Composite webs and closure systems

ABSTRACT

Composite webs having one or more polymeric structures located on a substrate, closure systems comprising composite webs, and methods of attaching articles are disclosed. The polymeric structures are formed using thermoplastic compositions and are attached to a surface of a substrate. The polymeric structures include an area that is attached to the substrate and a detached area that is not attached to a surface of a substrate.

RELATED APPLICATION

This application is a divisional of U.S. Ser. No. 10/744,141, filed Dec.22, 2003, now allowed, the disclosure of which is incorporated byreference in its entirety herein and which was a continuation-in-part ofU.S. patent application Ser. No. 10/387,699, filed Mar. 13, 2003.

FIELD OF THE INVENTION

The present invention relates to composite webs that include one or morepolymeric structures on a substrate, as well as methods and systems formanufacturing the composite webs.

BACKGROUND

The manufacture of articles formed of webs that require somereinforcement to withstand forces experienced during use are known. Inmany cases, reinforcement is simply provided over the entire substrateor web. Such approaches can, however, add cost and weight to the web, aswell as stiffness over the entire surface of the web—even in those areasthat do not require reinforcement. Furthermore, reinforcing layers thatare coextensive with the web may also reduce its breathability.

To address some of these issues, smaller pieces of reinforcing materialsmay be attached to a web or substrate in selected areas that requirereinforcement. The handling and attachment of such discrete pieces can,however, be problematic, by potentially reducing throughput, causingwaste (where the discrete pieces are not securely attached), requiringprecise registration or location on the web, requiring the use ofadhesives or other bonding agents, etc. The discrete pieces may alsopresent relatively sharp edges that may be the source of irritation ordiscomfort. The irritation or discomfort can be exacerbated because thereinforcing pieces are typically located on the surface of thesubstrate.

In addition to (or in place of) reinforcing substrates or webs, it mayalso be desirable to manufacture articles that exhibit elasticity. Themanufacture of articles that exhibit elasticity, i.e., the ability to atleast partially recover their original shape after moderate elongation,may be desired for a number of reasons. For example, elasticity may beuseful in connection with fastening systems for items such as garments(e.g., diapers, training pants, gowns, bedding, etc.). Elasticity ingarments can provide what may be referred to as dynamic fit, i.e., theability to stretch and recover in response to movement by the wearer.

Elasticity may also be useful in connection with other applications. Forexample, some fasteners may provide more consistent attachment if thefastener is held in tension that can be supplied by stretching thefastener and relying on the recovery forces to provide the desiredtension. In other instances, elasticity may allow for easy adjustment ofthe size or length of a fastener or other article.

Although elasticity may be beneficial in a variety of differentapplications, it may raise issues in manufacturing. Many attempts toprovide elasticity rely on separate elastic components that are, e.g.,glued or sewn to a backing or other nonelastic member to provide thedesired elasticity. The manufacture of such composite articles may beproblematic in that secure attachment of the elastic components may bedifficult to achieve and/or maintain. Further, the cost and difficultyof providing and attaching separate elastic components may be relativelyhigh. The handling and attachment of separate elastic components canreduce throughput, cause additional waste (where the separate componentsare not securely attached), etc.

In other instances, an entire article may be constructed to provide thedesired elasticity. For example, many elastic fastening systems rely onthe use of elastic laminate backings in which the elastic materials areprovided in the form of a film that is coextensive with the backing.Such an approach may add costs associated with providing a coextensiveelastic layer or layers. Further, many elastic materials are notbreathable. If the elastic laminate backings are to be used in garments,it may be desirable to perforate the backing to improve itsbreathability. Such additional processing does, however, add to the costof producing the elastic laminate backing. Another potentialdisadvantage of elastic laminate backings is that it may be difficult toprovide any adjustment of the elastic recovery forces generated indifferent portions of the backing.

While a variety of approaches to providing discrete polymeric structureson substrates are disclosed in, e.g., U.S. Patent ApplicationPublication No. U.S. 2003/0085485 A1, filed 5 Nov. 2001 and titledSYSTEMS AND METHODS FOR COMPOSITE WEBS WITH STRUCTURED DISCRETEPOLYMERIC REGIONS; U.S. Patent Application Publication No. U.S.2003/0087098 A1, filed 5 Nov. 2001 and titled COMPOSITE WEBS WITHREINFORCING POLYMERIC REGIONS AND ELASTIC POLYMERIC REGIONS; U.S. PatentApplication Publication No. U.S. 2003/0084996 A1, filed 5 Nov. 2001 andtitled METHODS FOR PRODUCING COMPOSITE WEBS WITH REINFORCING DISCRETEPOLYMERIC REGIONS; and U.S. Patent Application Publication No. U.S.2003/0087059 A1, filed 5 Nov. 2001 and titled COMPOSITE WEBS WITHDISCRETE ELASTIC POLYMERIC REGIONS, these approaches may be limited incertain aspects, such as in roll temperatures, the composition ofsubstrates, etc.

Closure elements and systems providing attaching means are well known.The art provides a large number of various systems comprising variousdesigns and materials. For example, U.S. Pat. No. 3,899,803 teaches aself gripping device which includes a sheet member including grippingelements having distinct gripping means integrally formed therein withina frame in substantially the same plane as the sheet. To be used asgripping elements the sheet is bent to force the gripping elements toproject perpendicular to the plane of the sheet.

Additionally, U.S. Pat. No. 5,983,467 teaches an interlocking devicewhich is generally effectuated by one or more islands on the surface ofa first portion which, when a relative shearing force is applied,slidingly engage one or more complementary apertures within a structureon the surface of a second portion. U.S. Pat. No. 4,887,339 teaches astrip of polymeric sheet material adapted to cut into lengths to formreleasably engageable pieces of a fastener. U.S. Pat. No. 4,183,121teaches a separable fastener composed of two opposed, mating elongatedstrips with a series of flexible interengaging tongues offset from andin parallel alignment with one of the axes of the strips, and partiallyoverlapping openings in the strips.

Despite the significant amount of art regarding closure elements andsystems, there is still a need for a closure system such as one thatprovides low profile, in-plane closure elements at a low cost. Suchclosure systems could be advantageously used for items such as, but notlimited to, packaging and disposable diapers.

SUMMARY OF THE INVENTION

The present invention provides composite webs having one or morepolymeric structures located on a substrate, composite webs, methods ofmanufacturing the composite webs, and systems for manufacturing thecomposite webs, as well as closure systems including composite webs, andmethods of attaching articles.

Composite webs having one or more polymeric structures may be attachedto a substrate such that, for example, a structure may be provided thatincludes both bonded areas and detached areas. Such structures mayadvantageously provide closure elements and closure systems that mayprovide closure by, e.g., engaging with fibers of a loop material,engaging with a loop-like material provided by extrusion processesdescribed herein, by a self-mating design as described herein, etc.

The polymeric structures are formed using thermoplastic compositions. Asused in connection with the present invention, “thermoplastic” (andvariations thereof) means a polymer or polymeric composition thatsoftens when exposed to heat and returns to its original condition ornear its original condition when cooled to room temperature. Thethermoplastic compositions used in connection with the methods of thepresent invention should be capable of flowing or entering intodepressions in a forming tool as described herein.

Suitable thermoplastic compositions are those that are melt processable.Such polymers are those that will flow sufficiently to at leastpartially fill the depressions, yet not significantly degrade during amelt process. A wide variety of thermoplastic compositions have suitablemelt and flow characteristics for use in the process of the presentinvention depending on the geometry of the depressions and theprocessing conditions. It may further be preferred that the meltprocessable materials and conditions of processing are selected suchthat any viscoelastic recovery properties of the thermoplasticcompositions do not cause them to significantly withdraw from thedepressions during wiping of the molten thermoplastic composition asdescribed herein.

In the methods and systems, the forming tool used to form and transferthe one or more polymeric structures to the substrate is maintained at aroll temperature that is below the melt processing temperature of thethermoplastic composition. The melt processing temperature of thethermoplastic compositions of the present invention is the lowesttemperature at which the thermoplastic composition is capable of flowingor entering into depressions in a forming tool (as described herein)within a period of five seconds or less.

In some instances, the melt processing temperature may be at or slightlyabove the glass transition temperature for an amorphous thermoplasticcomposition or at or slightly above the melting temperature for acrystalline or semicrystalline thermoplastic composition. If thethermoplastic composition includes one or more amorphous polymersblended with either or both of one or more crystalline and one or moresemicrystalline polymers, then the melt processing temperature is thehigher of the highest glass transition temperature of the amorphouspolymers or the highest melting temperature of the crystalline andsemicrystalline polymers. In addition, it may be preferred that the rolltemperature be at least 20° Celsius or more below the temperature of themolten thermoplastic composition deposited on the forming tool.

One potential advantage of maintaining a relatively cool forming tool isthat the molten thermoplastic composition applied to the forming tool(either on its cylindrical outer surface or within depressions formedtherein) is that the molten thermoplastic composition in direct contactwith the exterior roll surface falls below the melt processingtemperature of the thermoplastic composition such that it may at leastpartially freeze or solidify, while at least a portion of the moltenthermoplastic composition located distal from the exterior roll surfaceremains molten long enough to effect transfer of the thermoplasticcomposition to form the polymeric structures. The result is that themolten thermoplastic composition distal from the exterior roll surfaceis capable of attaching to a substrate, while the frozen or solidifiedthermoplastic composition in contact with the exterior roll surfacereleases from that surface cleanly.

Another potential advantage of maintaining a relatively cool formingtool is that the composition of the substrates to which the moltenthermoplastic composition is transferred is not limited by the formingtool temperature. For example, the roll temperature may be low enough tolimit any significant damage to the substrate during the transferprocess. As such, the polymeric structures may be formed on porous andnon-porous substrates (such as films) that have the same or similarthermoplastic composition as the polymeric structures. In some instancesinvolving substrates formed of thermoplastic compositions themselves,the substrate thermoplastic composition may preferably have a meltprocessing temperature that is at or below the melt processingtemperature of the thermoplastic composition used in the polymericstructures formed thereon. The melt processing temperature of thesubstrate thermoplastic compositions is subject to the same definitionprovided above in connection with the thermoplastic compositions used toform the polymeric structures. In addition, it may be preferred that theroll temperature be at least 20° Celsius or more below the meltprocessing temperature of the substrate thermoplastic composition.

Concerns regarding the internal cohesive strength of the substrateand/or the tensile strength of the substrate may be of more concern ifthe substrate includes a fibrous construction (e.g., woven, nonwoven, orknit fibers) that could be separated from the remainder of the substrateby the forces exerted when the substrate is pulled away from the formingtool. These considerations may be limited by the present inventionbecause of the freezing or solidification of the thermoplasticcomposition in the depressions. That freezing or solidification canlimit any forces exerted on the substrate as the substrate and thepolymeric structures are removed from the forming tool.

Another potential advantage of the methods of the present invention isthe ability to transfer one or more polymeric structures onto a majorsurface of a substrate while a portion of the thermoplastic compositionfacing the substrate is molten. If the substrate is porous, fibrous,etc., pressure may enhance attachment of the one or more polymericstructures to the substrate by forcing a portion of the thermoplasticcomposition to infiltrate the substrate and/or encapsulate fibers of thesubstrate. If the substrate is not porous, but is made with athermoplastic composition that has a melt processing temperaturesufficiently low relative to the temperature of the molten thermoplasticcomposition in the depressions, then attachment of the polymericstructures may be achieved by intermixing of the thermoplasticcompositions in the polymeric structures and the substrate.

Another potential advantage of the present invention is the opportunityto provide polymer structures that include surface features formed ontheir upper surfaces (i.e., the surfaces facing away from thesubstrate). The surface features may be, e.g., stems, hooks, pyramids,channels, indicia (alphanumeric or otherwise), etc. and may provideadditional functionality such as, e.g., mechanical fastening, etc. Thesesurface features may be provided in an integral process step at the sametime as formation and transfer of the polymer structures themselves (asopposed to a separate, subsequent process step). Alternatively, though,the surface features could be provided after formation of the polymerstructures.

Another potential advantage is the ability to control the shape,spacing, and volume of the one or more polymeric structures. In someinstances, it may be preferred that a plurality of polymeric structuresbe provided on the first major surface of the substrate, with each ofthe polymeric structures being discrete polymeric structures (i.e., notconnected to each other by the thermoplastic composition transferred tothe substrate).

Another potential advantage of the present invention may be found in theability to provide a thin base film between thicker thermoplasticcomposition structures. The thicker thermoplastic composition structuresare attached to the substrate, but the base film may or may not beattached to the substrate. The base film may be, e.g., attached to thesubstrate by adhesives.

Another potential advantage of the methods of the present invention isthe ability to provide one or more polymeric structures that extend forthe length of the substrate (while preferably not being formed over thewidth of the substrate, i.e., the polymeric structures are notcoextensive with the major surface of the substrate).

Another potential advantage of the methods of the present invention isthe ability to provide different thermoplastic compositions in differentareas across the width of the substrate, such that some polymericstructures may be formed of one thermoplastic composition, while otherpolymeric structures are formed of a different thermoplasticcomposition.

Yet another potential advantage of the methods of the present inventionis the ability to provide one or more polymeric structures on both majorsurfaces of a substrate. The polymeric structures on the opposing majorsurfaces may be formed with the same or different structures as desired.

In one aspect, the present invention provides a method for producing acomposite web by providing a forming tool having an exterior surfacethat includes one or more depressions formed therein; delivering amolten thermoplastic composition onto the exterior surface of theforming tool; maintaining the exterior surface of the forming tool at aroll temperature that is below a melt processing temperature of thethermoplastic composition; wiping the molten thermoplastic compositionon the exterior surface of the forming tool, wherein at least some ofthe molten thermoplastic composition enters the one or more depressions;transferring the thermoplastic composition in the one or moredepressions to a substrate by contacting a first major surface of thesubstrate to the thermoplastic composition in the one or moredepressions; and separating the substrate and the thermoplasticcomposition in the one or more depressions from the forming tool afterthe transferring. A composite web is formed that includes one or morepolymeric structures of the thermoplastic composition located on thefirst major surface of the substrate, wherein the area occupied by atleast one polymeric structure of the one or more polymeric structuresincludes a bonded area in which the thermoplastic composition of thepolymeric structure is attached to the first major surface of thesubstrate and at least one detached area in which the polymericstructure is not attached to the first major surface of the substrate.

In another aspect, the present invention provides a method for producinga composite web by providing a forming tool having an exterior surfacethat includes one or more depressions formed therein; delivering amolten thermoplastic composition onto the exterior surface of theforming tool; maintaining the exterior surface of the forming tool at aroll temperature that is below a melt processing temperature of thethermoplastic composition; wiping the molten thermoplastic compositionon the exterior surface of the forming tool, wherein at least some ofthe molten thermoplastic composition enters the one or more depressions;transferring the thermoplastic composition in the one or moredepressions to a substrate by contacting a first major surface of thesubstrate to the thermoplastic composition in the one or moredepressions; and separating the substrate and the thermoplasticcomposition in the one or more depressions from the forming tool afterthe transferring. A first portion of the thermoplastic composition inthe one or more depressions that is distal from the surfaces of the oneor more depressions remains at or above the melt processing temperatureof the thermoplastic composition at least until the thermoplasticcomposition in the one or more depressions contacts the first majorsurface of the substrate, and wherein a second portion of thethermoplastic composition in the one or more depressions that is distalfrom surfaces of the one or more depressions falls below the meltprocessing temperature after the depositing and before contacting thefirst major surface of the substrate. A composite web is formed thatincludes one or more polymeric structures of the thermoplasticcomposition located on the first major surface of the substrate, whereinthe area occupied by at least one polymeric structure of the one or morepolymeric structures includes a bonded area attached to the first majorsurface of the substrate and a detached area that is not bonded to thefirst major surface of the substrate, wherein the bonded area includesthe first portion of the thermoplastic composition and the detached areaincludes the second portion of the thermoplastic composition.

In another aspect, the present invention provides a composite webincluding a substrate having a first major surface; and one or morepolymeric structures of a thermoplastic composition attached to thefirst major surface of the substrate; wherein each polymeric structureof the one or more polymeric structures occupies an area of the firstmajor surface of the substrate. The area occupied by at least onepolymeric structure of the one or more polymeric structures includes abonded area in which the thermoplastic composition of the polymericstructure is attached to the first major surface and at least onedetached area in which the polymeric structure is not attached to thefirst major surface of the substrate. In the detached area, the at leastone polymeric structure is cantilevered over and aligned with the firstmajor surface of the substrate.

In another aspect, the present invention provides a composite webincluding a substrate with a first major surface; and one or morepolymeric structures of a thermoplastic composition attached to thefirst major surface of the substrate; wherein each polymeric structureof the one or more polymeric structures occupies an area of the firstmajor surface of the substrate. The area occupied by at least onepolymeric structure of the one or more polymeric structures includes abonded area in which the thermoplastic composition of the polymericstructure is attached to the first major surface and three or moredistinct detached areas extending from the bonded area, wherein thethree or more distinct detached areas are cantilevered over but notattached to the first major surface of the substrate.

In another aspect, the present invention provides a closure system thatincludes a first closure element including a thermoplastic polymericstructure attached to a first major surface of a first substrate,wherein the first closure element occupies an area of the first majorsurface of the first substrate. The area occupied by the first closureelement includes a bonded area in which the thermoplastic polymericstructure is attached to the first major surface of the first substrateand a detached area in which the thermoplastic polymeric structure isnot attached to the first major surface of the first substrate. Aportion of the thermoplastic polymeric structure in the detached areaforms a first cantilevered tab supported above the first major surfaceof the first substrate, wherein the bonded area of the first closureelement, the cantilevered tab of the first closure element, and thefirst major surface of the first substrate form a first pocket. Theclosure system also includes a second closure element including athermoplastic polymeric structure attached to a first major surface of asecond substrate. The second closure element occupies an area of thefirst major surface of the second substrate that includes, wherein thearea occupied by the second closure element includes a bonded area inwhich the thermoplastic polymeric structure is attached to the firstmajor surface of the second substrate and a detached area in which thethermoplastic polymeric structure is not attached to the first majorsurface of the second substrate. A portion of the thermoplasticpolymeric structure in the detached area forms a second cantilevered tabsupported above the first major surface of the second substrate, whereinthe bonded area of the second closure element, the cantilevered tab ofthe second closure element, and the first major surface of the secondsubstrate form a second pocket. The cantilevered tab of the firstclosure element is located in the second pocket and the cantilevered tabof the second closure element is located in the first pocket when theclosure system is in a closed configuration.

In another aspect, the present invention provides a closure system thatincludes a substrate having a first major surface and one or morepolymeric structures attached to the first major surface of thesubstrate, wherein each polymeric structure of the one or more polymericstructures occupies an area of the first major surface of the substrate.The area occupied by at least one polymeric structure of the one or morepolymeric structures includes a bonded area in which the thermoplasticcomposition of the polymeric structure is attached to the first majorsurface and at least one detached area in which the polymeric structureis not attached to the first major surface of the substrate. In thedetached area, the at least one polymeric structure is cantilevered overand aligned with the first major surface of the substrate. The closuresystem also includes a complementary surface having one or more openingscapable of receiving the detached areas of the one or more polymericstructures. In a closed configuration, the first major surface of thesubstrate faces the complementary surface and the at least one detachedarea of the at least one polymeric structure is located within the oneor more openings of the complementary surface such that movement of thecomplementary surface and the substrate relative to each other isrestricted.

In another aspect, the present invention provides a closure system thatincludes a substrate having a first major surface and one or morepolymeric structures attached to the first major surface of thesubstrate, wherein each polymeric structure of the one or more polymericstructures occupies an area of the first major surface of the substrate.The area occupied by at least one polymeric structure of the one or morepolymeric structures includes a bonded area in which the thermoplasticcomposition of the polymeric structure is attached to the first majorsurface and three or more distinct detached areas extending from thebonded area in which the polymeric structure is not attached to thefirst major surface of the substrate. In the three or more distinctdetached areas, the at least one polymeric structure is cantileveredover the first major surface of the substrate. The closure system alsoincludes a complementary surface including one or more openings capableof receiving the distinct detached areas of the one or more polymericstructures. In a closed configuration, the first major surface of thesubstrate faces the complementary surface and at least one of thedistinct detached areas of the at least one polymeric structure islocated within the one or more openings of the complementary surfacesuch that movement of the complementary surface and the substraterelative to each other is restricted.

These and other features and advantages of the present invention aredescribed below in connection with various illustrative embodiments ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of one polymeric structure on acomposite web manufactured according to the methods of the presentinvention.

FIG. 2 is a cross-sectional view of polymeric structures and a base filmon a composite web, with the base film being unattached to the substratebetween the polymeric structures.

FIG. 3 is a cross-sectional view of polymeric structures and a base filmon a composite web, with the base film attached to the substrate betweenthe polymeric structures.

FIG. 4 is a plan view of a portion of a forming tool including adepression in its exterior surface that can be used in manufacturingcomposite webs according to the methods of the present invention.

FIG. 5 is a cross-sectional view of the depression of FIG. 4 taken alongline 5-5 in

FIG. 4.

FIG. 6 is a plan view of alternative depressions on a forming tool thatcan be used to manufacture polymeric structures on a composite webaccording to the methods of the present invention.

FIG. 7 is an enlarged cross-sectional view of a portion of one of thedepression of FIG. 6, taken along line 7-7 in FIG. 6, wherein thedepression contain thermoplastic composition.

FIG. 8 is a plan view of a portion of another depression on a formingtool that can be used to manufacture polymeric structures on a compositeweb according to the methods of the present invention.

FIG. 9 is a cross-sectional view of the depression of FIG. 8, takenalong line 9-9 in

FIG. 8.

FIG. 10 is a plan view of one ring-shaped depression on a forming tool.

FIG. 11 is a cross-sectional view of the depression of FIG. 10, takenalong line 11-11 in FIG. 10.

FIG. 12 is a cross-sectional view of the depression of FIG. 10 takenalong line 12-12 in FIG. 10.

FIG. 13 is a cross-sectional view of a polymeric structure formed by thedepression of FIG. 10 on a substrate.

FIG. 14 is a cross-sectional view of a portion of a composite web withring-shaped polymeric structures on both major sides of a substrate.

FIG. 15 is a diagram of one polymer transfer system that may be used toprovide polymeric structures on a substrate in accordance with themethods of the present invention.

FIG. 16 is an enlarged schematic diagram depicting one relationshipbetween a doctor blade and depressions on a forming roll in the systemof FIG. 15.

FIG. 17 is an enlarged schematic diagram depicting one relationshipbetween a doctor blade and depressions on a forming roll in the systemof FIG. 15 in which a base film is formed on the exterior surface of theforming roll.

FIG. 18 is an enlarged partial cross-sectional view depicting aconformable backup roll forcing a substrate against a forming roll.

FIG. 19 illustrates another forming roll and polymer source useful inconnection with zoned delivery systems and methods.

FIG. 20 is a plan view of a portion of an exterior surface of a formingroll with a patterned depression formed therein.

FIG. 21 is a plan view of a composite web including a polymericstructure formed thereon using the forming roll of FIG. 20.

FIG. 22 is a cross-sectional view of the composite web of FIG. 21 afterstretching.

FIG. 23 is an alternative system for producing a polymeric structure ona composite web similar to that depicted in FIG. 20.

FIG. 24 is another alternative system for producing a polymericstructure on a composite web similar to that depicted in FIG. 20.

FIGS. 25A-25E are cross-sectional views of portions of alternativecomposite webs with two different thermoplastic compositions located ona surface of a substrate.

FIGS. 26 a-26 b depict a composite web including oval shaped closureelements. FIG. 26 a is a plan view of a plurality of oval shaped closureelements attached to a substrate. FIG. 26 b is a cross-sectional view ofa single oval shaped element of FIG. 26 a taken along line 26 b-26 b inFIG. 26 a.

FIGS. 27 a-27 b show a composite web including closure elements havingbarbs. FIG. 27 a is a plan view of a plurality of closure elementsattached to a substrate, the elements including detached areas with abarb on each detached region. FIG. 27 b is a cross-sectional view of aclosure element of FIG. 27 a taken along line 27 b-27 b depicted in FIG.27 a.

FIGS. 28 a-28 c show an additional embodiment of the composite webs ofthe invention having closure elements including barbs. FIG. 28 a is aplan view of a plurality of closure elements attached to a substrate.FIG. 28 b is an enlarged view of a single closure element of FIG. 28 a.FIG. 28 c is a cross-sectional view of a single closure element of FIG.28 b, taken along line 28 c-28 c depicted in FIG. 28 b.

FIGS. 29A-29C show additional embodiments of the composite webs of theinvention including closure elements. FIG. 29A is a plan view of aplurality of closure elements attached to a substrate. FIG. 29B is anenlarged plan view of some of the elements of FIG. 29A. FIG. 29C showsclosure elements of FIGS. 29A and 29B prepared using MD grooves in thedoctor blade to create regions to be bonded to the substrate.

FIG. 30 shows a plan view of the composite webs of the inventionincluding an alternative shape of the individual closure elements.

FIGS. 31 a-31 b show an alternative embodiment of the composite webs ofthe present invention that provides a closure system. This systemincludes a closure element having flexible elements. FIG. 31 a is a planview of a spring-type engaging member closure element, wherein theclosure element includes a bonded area and a detached area that isflexible and includes barbs. FIG. 31 b shows the spring-type engagingmember of FIG. 31 a in an engaged orientation with a complementaryslotted receiving member.

FIGS. 32 a-32 b show an embodiment of the composite web including raisedportions and surrounding valleys. FIG. 32 a is a perspective view of acomposite web including raised portions in the form of ridges. FIG. 32 bis a cross-sectional view of a composite web including raised portionsand surrounding valleys and further including polymeric structuresattached to the raised portions.

FIGS. 33 a-33 b show closure elements of a closure system includingtabs. FIG. 33 a depicts a first closure element attached to a substrate.FIG. 33 b is a cross-sectional view of the closure element of FIG. 33 amated with a complementary closure element on a second substrate, thecross-sectional view taken along line 33 b-33 b depicted in FIG. 33 a.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS OF THE INVENTION

As discussed above, the present invention provides composite webs thatinclude polymeric structures located on the surface of a substrate andthat provide closure elements and systems of the present invention.Various different constructions will now be described to illustratevarious embodiments of the closure elements and systems in accordancewith the present invention. These illustrative constructions should notbe considered to limit the present invention, which is to be limitedonly by the claims that follow.

As used herein, the term, “occupies” in reference to the closureelements and systems of the invention is understood to mean the elementor system is located directly above a surface of a substrate or isattached to a surface of a substrate, and includes the circumstance inwhich an element or system includes both an area directly above asurface of a substrate and an area attached to a surface of a substrate.

As used herein, the term “fiber” includes fibers of indefinite length(e.g., filaments) and fibers of discrete length, e.g., staple fibers.The fibers used in connection with the present invention may bemulticomponent fibers. The term “multicomponent fiber” refers to a fiberhaving at least two distinct longitudinally coextensive structuredpolymer domains in the fiber cross-section, as opposed to blends wherethe domains tend to be dispersed, random, or unstructured. The distinctdomains may thus be formed of polymers from different polymer classes(e.g., nylon and polypropylene) or be formed of polymers from the samepolymer class (e.g., nylon) but which differ in their properties orcharacteristics. The term “multicomponent fiber” is thus intended toinclude, but is not limited to, concentric and eccentric sheath-corefiber structures, symmetric and asymmetric side-by-side fiberstructures, island-in-sea fiber structures, pie wedge fiber structures,and hollow fibers of these configurations.

FIG. 1 is a cross-sectional view of a portion of one composite webmanufactured in accordance with the present invention. The composite webincludes a substrate 10 with a first major surface 11 and a second majorsurface 12. One or more polymeric structures 14 are located on the firstmajor surface 11 of the substrate 10, it being understood that thesubstrate may include more than one polymeric structure.

The polymeric structures 14 may cover any desired portion of the surface11 of the substrate 10 on which they are positioned, although it will beunderstood that the polymeric structures 14 will not cover all of thesurface of the substrate 10. For example, it may be preferred that thepolymeric structures occupy less than all of the first major surface ofthe substrate, preferably less than 75% of the first major surface ofthe substrate, and optionally less than 50% of the first major surfaceof the substrate. At the lower end of the range, it may be preferredthat the polymeric structures occupy at least 2% of the first majorsurface of the substrate, preferably 5% or more of the first majorsurface of the substrate, and optionally 10% or more of the first majorsurface of the substrate. Additional variations in the percentage ofsurface area occupied by polymeric structures may be as described in,for example, pending U.S. patent application Ser. No. 09/257,447,entitled WEB HAVING DISCRETE STEM REGIONS, filed on Feb. 25, 1999(published as International Publication No. WO 00/50229).

FIG. 2 depicts an alternative composite web construction in whichpolymer structures 114 are attached to the major surface 111 of asubstrate 110. The polymeric structures 114 are, however, connected toeach other by a thin base film 116. The base film 116 will typically beproduced while forming and transferring to polymeric structures 114 tothe substrate 110. Furthermore, the base film 116 will typically bemanufactured of the same thermoplastic composition as the polymericstructures 114. Some exemplary processes of manufacturing polymericstructures with base films are described more completely below.

The base film 116 may be removed from the composite web after attachmentof the polymeric structures 114 or it may be left in place. As seen inFIG. 2, the base film 116 may not be attached directly to the surface111 of the substrate 110 over its entire surface. In such anarrangement, the base film 116 may be retained as a part of thecomposite web by attachment to the substrate 110 near the edges of thepolymeric structures 114 and/or by attachment of the base film 116 tothe polymeric structures 114 themselves.

The polymeric structures 114 and the base film 116 can be distinguishedfrom each other in the composite web construction by their relativethickness. The polymeric structures 114 will have a maximum thickness(measured normal to the localized surface 111 of the substrate 110) thatis greater than the maximum thickness of the base film 116. For example,the base film 116 may preferably have a maximum thickness that is 25% orless (more preferably 10% or less) of the maximum thickness of thepolymeric structures 114 formed by depressions on the forming tool.

FIG. 3 depicts a composite web in which the base film 116 between thepolymeric structures 114 is attached to the surface 111 of the substrate110. In some instances, the base film 116 may be attached to thesubstrate 110 at the same time the polymeric structures 114 are attachedthereto using the same mechanism used to attach the polymeric structures114 (e.g., infiltration of the substrate 110 by the thermoplasticcomposition in the base film 116, intermixing of the thermoplasticcomposition of the base film 116 with the a substrate thermoplasticcomposition, etc.).

In other instances, the base film 116 may be attached to the substrate110 after the polymeric structures 114 are attached thereto. Forexample, the base film 116 may be attached to the substrate 110 by,e.g., heat welding, chemical welding, heat sealing, pressure welding,lasers, ultrasonic energy, etc.

In the depicted embodiment, however, the base film 116 is attached tothe surface 111 of the substrate 110 by adhesive 118 interposed betweenthe base film 116 and the surface 111. The adhesive 118 may be anysuitable composition, e.g., curable, pressure sensitive, heat activated,hot melt, etc. In addition, the adhesive 118 may be provided on thesurface 111 of the substrate 110 before contacting the substrate withthe base film 116 and polymeric structures 114, or it may provided onthe base film 116 before contacting the base film 116 with the substrate110.

Although adhesive 118 is not depicted as being located between thepolymeric structures 114 and the substrate 110, it may be provided inthose locations. The conditions (e.g., heat, pressure, etc.) encounteredduring attachment of the polymeric structures 114 to the substrate 110may, however, result in degradation, etc. of the adhesive such that theadhesive 118 does not function as the primary mechanism of attachment tothe substrate 110.

The polymeric structures on composite webs of the present invention maybe uniformly spaced over the surface of the substrate in a regular,repeating pattern (in both the x and y directions) or the spacing andarrangement of polymeric structures may be non-uniform if so desired.Furthermore, the pattern in which the polymeric structures are arranged,may be irregular.

In other variations, portions of the composite webs manufactured inaccordance with the present invention may include uniformly-spacedpolymeric structures, while other portions of the same composite web maybe free of any polymeric structures. In yet another alternative,portions of a composite web manufactured in accordance with the presentinvention may include uniformly spaced polymeric structures, while otherportions of the same composite web may include polymeric structures thatare arranged in non-uniformly spaced patterns. Further, differentportions of a composite web manufactured according to the presentinvention may include different sets of polymeric structures that areboth uniformly spaced in repeating patterns that are different from eachother.

The polymeric structures could be provided in any desired shape, e.g.,squares, rectangles, hexagons, etc. The shapes may or may not be in theform of recognized geometric shapes, but may be randomly formed withirregular perimeters. In addition, the shapes may not necessarily besolid figures, but may include islands formed within the shape in whichnone of the thermoplastic composition is transferred or a base film istransferred. In yet another alternative, some or all of the polymericstructures may be in the form of indicia, i.e., letters, numbers, orother graphic symbols.

The substrates used in connection with the composite webs of the presentinvention may have a variety of constructions. For example, thesubstrates may be a woven material, nonwoven material, knit material,netting, scrim, foam, paper, film, or any other continuous media thatcan be fed through a nip point. The substrates may have a wide varietyof properties, such as extensibility, elasticity, flexibility,conformability, breathability, porosity, stiffness, etc. Further, thesubstrates may include pleats, corrugations, microcreping, or otherdeformations from a flat planar sheet configuration.

Unlike processes in which the substrates are contacted by rolls that areheated to temperatures that may result in softening or melting of thesubstrates such that the substrates lose their mechanical stability, themethods and systems of the present invention use rolls that arepreferably maintained at temperatures that are below the temperaturesthat may result in softening or melting such that the substrates losetheir mechanical stability. One potential advantage is that thesubstrates may be manufactured of the same or similar thermoplasticcompositions as those found in the polymeric structures and base films.For example, it may be possible to apply polymeric structures of apolyolefin thermoplastic composition to a substrate that includes thesame or similar thermoplastic composition (e.g., polypropylene polymericstructures on a polypropylene substrate).

In some instances, the substrates may exhibit some level ofextensibility and also, in some instances, elasticity. Extensible websthat may be preferred may have an initial yield tensile force of atleast about 50 gm/cm, preferably at least about 100 gm/cm. Further, theextensible webs may preferably be extensible nonwoven webs.

Suitable processes for making a nonwoven web that may be used inconnection with the present invention include, but are not limited to,airlaying, spunbond, spunlace, bonded melt blown webs and bonded cardedweb formation processes. Spunbond nonwoven webs are made by extruding amolten thermoplastic, as filaments from a series of fine die orifices ina spinneret. The diameter of the extruded filaments is rapidly reducedunder tension by, for example, by non-eductive or eductive fluid-drawingor other known spunbond mechanisms, such as described in U.S. Pat. No.4,340,563 (Appel et al.); U.S. Pat. No. 3,692,618 (Dorschner et al.);U.S. Pat. Nos. 3,338,992 and 3,341,394 (Kinney); U.S. Pat. No. 3,276,944(Levy); U.S. Pat. No. 3,502,538 (Peterson); U.S. Pat. No. 3,502,763(Hartman) and U.S. Pat. No. 3,542,615 (Dobo et al.). The spunbond web ispreferably bonded (point or continuous bonding).

The nonwoven web layer may also be made from bonded carded webs. Cardedwebs are made from separated staple fibers, which fibers are sentthrough a combing or carding unit which separates and aligns the staplefibers in the machine direction so as to form a generally machinedirection-oriented fibrous nonwoven web. However, randomizers can beused to reduce this machine direction orientation.

Once the carded web has been formed, it is then bonded by one or more ofseveral bonding methods to give it suitable tensile properties. Onebonding method is powder bonding wherein a powdered adhesive isdistributed through the web and then activated, usually by heating theweb and adhesive with hot air. Another bonding method is pattern bondingwherein heated calender rolls or ultrasonic bonding equipment are usedto bond the fibers together, usually in a localized bond pattern thoughthe web can be bonded across its entire surface if so desired.Generally, the more the fibers of a web are bonded together, the greaterthe nonwoven web tensile properties.

Airlaying is another process by which fibrous nonwoven webs useful inthe present invention can be made. In the airlaying process, bundles ofsmall fibers usually having lengths ranging between 6 to 19 millimetersare separated and entrained in an air supply and then deposited onto aforming screen, often with the assistance of a vacuum supply. Therandomly deposited fibers are then bonded to one another using, forexample, hot air or a spray adhesive.

Meltblown nonwoven webs may be formed by extrusion of thermoplasticpolymers from multiple die orifices, which polymer melt streams areimmediately attenuated by hot high velocity air or steam along two facesof the die immediately at the location where the polymer exits from thedie orifices. The resulting fibers are entangled into a coherent web inthe resulting turbulent airstream prior to collection on a collectingsurface. Generally, to provide sufficient integrity and strength for thepresent invention, meltblown webs must be further bonded such as bythrough air bonding, heat or ultrasonic bonding as described above.

A web can be made extensible by skip slitting as is disclosed in, e.g.,International Publication No. WO 96/10481 (Abuto et al.). If an elastic,extensible web is desired, the slits are discontinuous and are generallycut on the web prior to the web being attached to any elastic component.Although more difficult, it is also possible to create slits in thenonelastic web layer after the nonelastic web is laminated to theelastic web. At least a portion of the slits in the nonelastic webshould be generally perpendicular (or have a substantial perpendicularvector) to the intended direction of extensibility or elasticity (the atleast first direction) of the elastic web layer. By generallyperpendicular it is meant that the angle between the longitudinal axisof the chosen slit or slits and the direction of extensibility isbetween 60 and 120 degrees. A sufficient number of the described slitsare generally perpendicular such that the overall laminate is elastic.The provision of slits in two directions is advantageous when theelastic laminate is intended to be elastic in at least two differentdirections.

A nonwoven web used in connection with the present invention can also bea necked or reversibly necked nonwoven web as described in U.S. Pat.Nos. 4,965,122; 4,981,747; 5,114,781; 5,116,662; and 5,226,992 (all toMorman). In these embodiments the nonwoven web is elongated in adirection perpendicular to the desired direction of extensibility. Whenthe nonwoven web is set in this elongated condition, it will havestretch and recovery properties in the direction of extensibility.

The substrates used in connection with the present invention maypreferably exhibit some porosity on one or both of the major surfaces ofthe substrate such that when a molten thermoplastic composition isprovided on one of the major surfaces of the substrate, a mechanicalbond is formed between the molten thermoplastic composition and thesubstrate as the molten thermoplastic composition infiltrates and/orencapsulates a portion of the porous surface of the substrate. As usedin connection with the present invention, the term “porous” includesboth structures that include voids formed therein, as well as structuresformed of a collection of fibers (e.g., woven, nonwoven, knit, etc.)that allow for the infiltration of molten thermoplastic composition intothe interstices between fibers. If the porous surface includes fibers,the thermoplastic composition may preferably encapsulate fibers orportions of fibers on the surface of the substrate.

If the substrate is not porous (e.g., is a film such as a polymericfilm), but is made with a thermoplastic composition that has a meltprocessing temperature sufficiently low relative to the temperature ofthe molten thermoplastic composition in the depressions, then attachmentof the polymeric structures may be achieved by intermixing (e.g.,surface mixing as seen in, e.g., fusion bonding or heat sealing of,e.g., polymeric materials) of the thermoplastic compositions in thepolymeric structures and the substrate. To attach polymeric structuresin accordance with the present invention on substrates formed ofthermoplastic compositions themselves, the substrate thermoplasticcomposition may preferably have a melt processing temperature that is ator below the melt processing temperature of the thermoplasticcomposition used in the polymeric structures formed thereon.

The type and construction of the material or materials in the substrateshould be considered when selecting an appropriate substrate to which amolten thermoplastic composition is applied. For example, the substrateshould have sufficient internal strength such that it does not fallapart during the process. Preferably, the substrate has sufficientstrength in the machine direction at the temperature of the forming toolto remove it intact from the forming tool.

Although the substrates depicted in the various cross-sectional views ofthe articles manufactured according to the methods of the presentinvention are illustrated as single layer structures, it should beunderstood that the substrates may be of single or multi-layerconstruction. If a multi-layer construction is used, it will beunderstood that the various layers may have the same or differentproperties, constructions, etc. Some of these variations may be asdescribed in, for example, pending U.S. patent application Ser. No.09/257,447, entitled WEB HAVING DISCRETE STEM REGIONS, filed on Feb. 25,1999 (published as International Publication No. WO 00/50229).

The polymeric structures of the present invention may be formed of awide variety of different thermoplastic polymeric materials. Someexamples of thermoplastic compositions that may be used in connectionwith the present invention include, but are not limited to,polyurethanes, polyolefins (e.g., polypropylenes, polyethylenes, etc.),polystyrenes, polycarbonates, polyesters, polymethacrylates, ethylenevinyl acetate copolymers, ethylene vinyl alcohol copolymers,polyvinylchlorides, acrylate modified ethylene vinyl acetate polymers,ethylene acrylic acid copolymers, nylons, fluorocarbons, etc. Suitablethermoplastic polymers will generally have a melt flow index of 5-200grams/10 minutes measured at the appropriate conditions for the polymeras specified in ASTM D 1238. Furthermore, the thermoplastic compositionmay be, e.g., a thermoplastic hot melt adhesive.

The thermoplastic compositions of the present invention may includeeither or both of nonelastomeric or elastomeric thermoplastic polymers.A nonelastomeric thermoplastic polymer is one that is melt processableand that returns to its original condition or near its originalcondition upon cooling and which does not exhibit elastomeric propertiesat ambient conditions (e.g., room temperature and pressure). As used inconnection with the present invention, “nonelastomeric” means that thematerial will not substantially resume its original shape after beingstretched. Further, the nonelastomeric polymers may preferably sustainpermanent set following deformation and relaxation, which set ispreferably at least about 20 percent or more, and more preferably atleast about 30 percent or more of the original length at moderateelongation, e.g., about 50% (for those materials that can even bestretched up to 50% without fracture or other failure).

An elastomeric (or elastic) thermoplastic polymer is one that melts andreturns to its original condition or near its original condition uponcooling and exhibits elastomeric properties at ambient conditions (e.g.,room temperature and pressure). As used in connection with the presentinvention, “elastomeric” means that the material will substantiallyresume its original shape after being stretched. Further, theelastomeric polymers may preferably sustain only small permanent setfollowing deformation and relaxation which set is preferably no greaterthan about 30 percent and more preferably no greater than about 20percent of the original length at moderate elongation, e.g., about 50%.The elastomeric thermoplastic compositions of the present invention canbe both pure elastomers and blends with an elastomeric phase or contentthat will still exhibit substantial elastomeric properties at roomtemperature. U.S. Pat. No. 5,501,679 (Krueger et al.) provides somefurther discussion regarding elastomeric materials that may beconsidered for use in connection with the present invention.

The elastic thermoplastic compositions can include one or more polymers.For example, the polymer composition could be a blend with anelastomeric phase such that the polymer exhibits elastomeric propertiesat room temperature. Suitable elastic thermoplastic polymer compositionsmay include block copolymers such as conventional A-B or A-B-A blockcopolymers (e.g., styrene-isoprene-styrene, styrene-butadiene-styrene,styrene-ethylene-butylene-styrene block copolymers), elastomericpolyurethanes, olefinic elastomers, particularly elastomeric ethylenecopolymers (e.g., ethylene vinyl acetates, ethylene/octene copolymerelastomers, ethylene/propylene/diene terpolymer elastomers), as well asmixtures of these with each other, with other elastic thermoplasticpolymers, or with nonelastic thermoplastic polymers.

The thermoplastic compositions used in connection with the presentinvention can also be combined with various additives for desiredeffect. These include, for example, fillers, viscosity reducing agents,plasticizers, tackifiers, colorants (e.g., dyes or pigments),antioxidants, antistatic agents, bonding aids, antiblocking agents, slipagents, stabilizers (e.g., thermal and ultraviolet), foaming agents,microspheres, glass bubbles, reinforcing fibers (e.g., microfibers),internal release agents, thermally conductive particles, electricallyconductive particles, and the like. The amounts of such materials thatcan be useful in the thermoplastic compositions can be readilydetermined by those skilled in the art of processing and using suchmaterials.

FIG. 4 is a plan view of one exemplary depression 34 in transfer roll 30of the present invention, while FIG. 5 is a cross-sectional view of thedepression 34 taken along line 5-5 in FIG. 4. The depression 34 has acircular footprint (i.e. shape of the opening into the depression 34 atthe surface 32 of the roll) with a diameter represented by the letter d.The depression 34 has a depth (represented by the letter h) measuredfrom the exterior surface 32 of the transfer roll 30.

Forming tools used in connection with the present invention preferablyinclude depressions that are large enough to form polymeric structureson a substrate. The depressions and/or the polymeric structures formedaccording to the principles of the present invention may becharacterized in a variety of manners. For example, the depressions 34may be characterized in terms of the area occupied by their footprint onthe exterior surface of the forming tool, a maximum dimension of thefootprint (in any direction on the surface of the roll), the volume ofthe depression, the shape of the footprint, etc.

When characterized in terms of the area occupied by the footprint of thedepressions, each of the depressions 34 may have a footprint with anarea of about 4 square millimeters (mm²) or more. In other situations,each of the depressions 34 may have footprints with an area of about 8mm² or more.

Another manner in which the depressions may be characterized is in termsof the largest footprint dimension as measured on the surface 32 of thetransfer roll 30. For a depression with a circular footprint as seen inFIGS. 4 and 5, the largest dimension is the same in all directions, butthe depressions used in connection with the present invention may takeany desired shape (e.g. elongated, irregular, etc.) in which the largestdimension will occur in one or more directions on the exterior surfaceof the transfer roll 30, but not in others. When characterized in termsof the largest footprint dimension, it may be that the depressions havea largest footprint dimension of about 2 millimeters (mm) or more, insome instances about 5 mm or more.

Where elongated strands are formed as a part of the polymeric structures(either by grooves in the forming tool or by strands of thermoplasticcomposition deposited on the exterior surface of the forming tool), itmay be preferred that the strands have a width of 1 millimeter or moremeasured in a direction transverse to their length.

Yet another manner in which the depressions used in connection with thepresent invention may be characterized is in terms of volume. Forexample, the depressions may have a depression volume of at least aboutthree (3) cubic millimeters (mm³) or more, or alternatively, adepression volume of about five (5) cubic millimeters.

FIGS. 6 and 7 depict another set of depressions on a forming tool 130 inwhich the depressions 134 are oriented substantially along the face ofthe roll 130 (i.e., generally aligned with axis 131). The roll 130 isdesigned to rotate about axis 131 in use and, as a result, thedepressions 134 would typically deposit polymeric structures that areoriented in a cross-web direction (as opposed to a down web or machinedirection). Although more than one depression 134 is depicted on theexterior surface 132 of the roll 130, it will be understood that theroll may include only one such depression formed in its exterior surface132 if so desired.

The cross-sectional view of FIG. 7 (taken along line 7-7 in FIG. 6)depicts another optional feature of depressions in forming tools of thepresent invention. The depression 134 includes shallower areas 135 anddeeper areas 136. The depth of the different areas is measured normal tothe exterior surface 132 of the forming tool 130. For example, thedeeper area 136 has a height h as seen in FIG. 7.

In FIG. 7, the depression 134 includes thermoplastic composition 141located therein. The thermoplastic composition 141 within the depression134 preferably exhibits two different properties that, in FIG. 7, aredemarcated by broken line 146. The portion of the thermoplasticcomposition 141 proximate the surface 137 of the depression 134 (e.g.,between the surface 137 and broken line 146) may preferably fall belowthe melt processing temperature of the thermoplastic composition 141after it is deposited into the depression 134 but before thethermoplastic composition 141 in the depression 134 is contacted by asubstrate (as discussed in more detail below). In some instances it maybe possible to characterize the portion of the thermoplastic composition141 that has fallen below the melt processing temperature as havingfrozen, solidified, formed a skin layer, etc.

In contrast, the portion of the thermoplastic composition 141 distalfrom the surfaces 137 of the depression 134 (e.g., on the opposite sideof broken line 146) preferably remains at or above the melt processingtemperature of the thermoplastic composition 141 at least until thethermoplastic composition 141 in the depression 134 is contacted by asubstrate. Because the distal portion of the thermoplastic composition141 remains at or above the melt processing temperature, it may be,e.g., characterized as molten. That distal portion of the thermoplasticcomposition 141 that remains at or above the melt processing temperaturemay be available to infiltrate a porous substrate or intermix with apolymeric substrate as described herein.

It should be understood that although broken line 146 demarcates a sharpboundary, the actual boundary between molten and solidified or frozenthermoplastic composition 141 may not be a sharp line, but, rather, atransition zone having a depth.

Another feature depicted in connection with FIG. 7 is the larger mass ofthermoplastic composition 141 that fills the area 136 as compared to thesmaller mass of molten thermoplastic composition that fills theshallower portions 135 of the depression 134 during processing. Thosedifferent amounts of thermoplastic composition in the different areascan provide a number of advantages.

One potential advantage is that the locally increased mass ofthermoplastic composition 141 in area 136 may preferably include alarger mass of thermoplastic composition 141 that remains at or abovethe melt processing temperature as compared to the thermoplasticcomposition 141 in the shallower areas 135. The larger mass ofthermoplastic composition 141 at or above the melt processingtemperature within area 136 may be more effective at, e.g., infiltratinga porous substrate or intermixing with the same or different polymersin, e.g., a polymeric film substrate under the transfer conditions.Conversely, the smaller amount of thermoplastic composition 141 at orabove the melt processing temperature in the shallower areas 135 may beless effective at, e.g., infiltrating a porous substrate or intermixingwith the same or different polymers in, e.g., a polymeric film substrateunder the transfer conditions.

In some instances, all of the thermoplastic composition 141 in theshallower areas 135 may fall below the melt processing temperaturebefore contacting a substrate such that the thermoplastic composition141 in the shallower areas 135 will not infiltrate or intermix with thesubstrate. In those same instances, however, it is preferred that atleast a portion of the thermoplastic composition 141 in the deeper areas136 remain at or above the melt processing temperature to retain itsability to infiltrate and/or intermix with a substrate such that bondsare formed between the thermoplastic composition in the depression 134and the substrate.

The different amounts of thermoplastic composition 141 remaining at orabove the melt processing temperature in the different areas 135 and 136may contribute to the formation of a polymeric structure can bedescribed as exhibiting differential bonding characteristics. The areasof the resulting polymeric structure that bond to the substrate(typically those corresponding generally to the deeper areas 136 inwhich more or at least some of the thermoplastic composition 141 remainsat or above the melt processing temperature) can be described as “bondedareas.” The portions of the polymeric structure that correspond to theshallower area 135 of depression 134 (typically those areas in whichnone of or less of the thermoplastic composition 141 remains at or abovethe melt processing temperature) may typically form limited or no bondwith the substrate and, as such, may be referred to herein as a“detached area” of the polymeric structure formed by depression 134.

The depressions 134 depicted in FIGS. 6 and 7 represent one manner inwhich a locally increased mass of molten thermoplastic composition maybe delivered in a larger depression. The depression 234 of FIGS. 8 and 9preferably has a constant depth from the exterior surface 232 of theforming tool 230 along its length (see, e.g., the cross-sectional viewof FIG. 9). A locally increased mass of molten thermoplastic compositioncan, however, be delivered by area 236 in which the depression 234widens as compared to the narrower surrounding areas 235 of depression234. As a result, the widened area 236 delivers a locally increased massof molten thermoplastic composition that provide the differentialbonding characteristics discussed above with respect to depression 134of FIGS. 6 and 7. It should also be understood that the two featuresdepicted in FIGS. 6-8 may be combined, e.g., depressions may be providedwith locally increased masses of thermoplastic composition that arecontained in areas that are both deeper and wider than the surroundingdepression.

Depressions such as those depicted in FIGS. 6-8 may, in some instances,be characterized by volume differentials in one or more directions. Forexample, it may be preferred that, for elongated depressions, the areasof locally increased mass have a volume per unit length that is 125% ormore (preferably 150% or more) of the volume per unit length of thesurrounding depression.

Still another manner in which a locally increased mass of moltenthermoplastic composition may be delivered to a substrate to achieve,e.g., differential bonding of a polymeric structure can be describedwith reference to FIGS. 23 & 24 below. In those processes, moltenthermoplastic composition is applied over a mass of thermoplasticcomposition in a depression as, e.g., a strand of molten thermoplasticcomposition. Those areas in which the molten thermoplastic compositionextends over molten thermoplastic composition in a depression mayprovide the locally increased mass of thermoplastic composition neededto form a differentially bonded polymer structure on a substrate.

FIGS. 10-13 depict still other variations in the depressions used toprovide polymeric structures on substrates in connection with themethods of the present invention. The ring-shaped depression 334 islocated in the surface 332 of a forming tool in the form of an elongatedtrough with an island 333 located in the ring formed by depression 334.Although the depicted ring-shaped depression 334 is an elongatedoval-like shape, ring shaped depressions of the present invention may beformed in any desired shape, e.g., circular, square, triangular, etc.

Depressions that include islands such as that depicted in FIG. 10 can beused to provide polymeric structures on a substrate in which a portionof the substrate is exposed within a surrounding polymer structure or inwhich a base film is provided within a surrounding polymer structure.The resulting construction may, for example, be used to reinforce thesubstrate in the area of, e.g., a buttonhole, slot, perforation, orother opening formed on in the substrate. Other uses for similarstructures may also be envisioned.

The island 333 formed in the center of depression 334 may be the sameheight as the exterior surface 332 of the forming tool that surroundsthe depression 334. Although the depression 334 is depicted with only asingle island 333 formed therein, depressions used in connection withthe methods of the present invention may include two or more islandslocated within each depression if so desired. Furthermore, the shape ofthe island and surrounding depression may also vary, e.g., a depressionthat has a circular outermost perimeter may be paired with an islandhaving a different shape. In another variation, the island may not becentered within the depression as depicted in FIG. 10.

The orientation of the depression 334 on a forming tool 330 may beselected based on a variety of factors. The depression 334 may bealigned in the machine direction (i.e., the direction of travel of asubstrate), in the cross-web direction (i.e., transverse to thedirection of travel of the substrate), or any other orientation betweenmachine direction or cross-web direction.

Another variation depicted in FIG. 11 is the variation in depth of thedepression 334, with the depression being deepest proximate the islandand rising to a shallower depth at the outermost perimeter of thedepression 334. Such a construction may provide a polymeric structurewith more flexible edges due to thinning of the polymeric structure.

FIG. 12 depicts another optional variation in the depression of FIG. 10.As seen in the cross-sectional view of FIG. 12, the depth of thedepression 334 from the exterior surface of the 332 of the forming tool330 may vary with an area 335 being shallower than the deeper area 336.That deeper area 336 of depression 334 provides a locally increased massof molten thermoplastic composition for transfer to a substrate.

One example of a polymeric structure 314 that can be formed on surface311 of substrate 310 by the depression 334 is depicted in FIG. 13. Thepolymeric structure 314 occupies an area on the surface 311 of substrate310. The area occupied by the polymeric structure 314 can be describedas including a detached area 315 corresponding to the shallower area 335of depression 334 and a bonded area 316 corresponding to the area 336 ofdepression 334. The substrate 310 may be porous on the surface 311. As aresult, the increased mass of thermoplastic composition in the area 336results in infiltration of the of the substrate 310 by the thermoplasticcomposition within the bonded area 316 of the polymeric structure 314 asdepicted by the broken line within the body of the substrate 310. Incomparison, the reduced mass of thermoplastic composition in the area335 of depression 334 results in little or no infiltration of thesubstrate 310 by the thermoplastic composition in the detached area 315of the polymeric structure 314. As a result, the polymeric structure 314can be described as differentially bonded to the substrate 310.

In some instances the differential bonds can be characterized bypenetration of the thermoplastic composition into a porous substrate.For example, the thermoplastic composition within the bonded area 316may preferably infiltrate the porous substrate 310 to a depth of atleast 50% of the thickness of the porous portion of the substrate 310(which, in the case of the depicted substrate 310, the porous portion isall of the thickness of the substrate). In contrast, the thermoplasticcomposition within the detached area 315 may preferably infiltrate thesubstrate 310 to a depth of 25% or less of the thickness of the porousportion of the substrate 310. In the depicted example, the thermoplasticcomposition in the detached area 315 does not infiltrate the substrate310 at all.

If the surface 311 of the substrate 310 is not porous, but is, forexample, a film manufactured of a thermoplastic composition, thedifferential bonding characteristic described above may also beachieved, with the bonded area 316 being attached by, e.g., intermixingof the molten thermoplastic composition of the polymeric structure 314with the thermoplastic composition of the surface 311 of the substrate310. The thermoplastic composition of the polymer structure 314 in thedetached area 315 may exhibit little or no intermixing with thethermoplastic composition on the surface 311 of the substrate 310.

Another variation illustrated in connection with FIGS. 12 & 13 are thesurface features 352 formed on the upper surface 354 of the polymericstructure 314 (where the upper surface 354 generally faces away from thesubstrate 310). The surface features 352 may include, for example, stems(capped or otherwise), hooks (as part of a hook and loop fasteningsystem), pyramids, indicia (alphanumeric or otherwise), etc. Althoughthe surface features 352 may be useful in mechanical fastening systems,the surface features provided on polymeric structures of the presentinvention may serve other functions including, but not limited to, gripenhancement, abrasion, polishing, etc. Furthermore, it should beunderstood that surface features may be provided on all or only some ofthe polymeric structures.

The surface features 352 of FIG. 13 are depicted as stems oriented at anacute angle with respect to the surface 354 of the polymeric structure314. Although the stems are depicted as having substantially constantdimensions, they may be tapered, bent, capped, or otherwise formed toenhance their use as, e.g., mechanical fasteners. Furthermore, althoughthe stems are depicted as angled in one direction, they mayalternatively be angled in different directions and/or oriented normalto the surface 354.

The orientation of the stems depicted in FIG. 13 may be advantageous fora number of reasons. For example, the angled stems may not require a capor other structure to engage a loop surface or other fibrous substrateadapted to engage the stems. The composite web depicted in FIG. 13 mayexhibit the ability to fasten to a loop or other surface in a selecteddirection while releasing when the web is moved in the oppositedirection. Such a construction may be particularly useful in connectionwith an elastic substrate.

The angled orientation of the stems depicted in FIG. 13 may be providedin a variety of manners. For example, the stems may be manufacturedusing a tool having holes or cavities that are angled or tilted in thedesired direction or directions. Alternatively, the stems may be bentafter formation.

The depression 334 seen in FIG. 12 includes cavities 350 in which thesurface features 352 are formed by a thermoplastic composition fillingthe depression 334 (the cavities 350 are also depicted in the plan viewof FIG. 10). The shape, size, spacing, depth and other characteristicsof the cavities 350 may vary depending on factors such as thethermoplastic composition being used, the temperature of thethermoplastic composition delivered to the depression, etc.

The shape or profile of the cavities (and the resulting surface features352 they form) may differ from those depicted in connection with FIGS.12 & 13. For example, the cavities may be formed in more of ahook-shape, have tapered diameters, etc. Some example of alternativelyshaped cavities and the structures that may be formed using them aredepicted in, e.g., U.S. Pat. No. 5,792,411 (entitled LASER MACHINEDREPLICATION TOOLING), U.S. Pat. No. 6,190,594 B1 (entitled TOOLING FORARTICLES WITH STRUCTURED SURFACES), U.S. Pat. No. 6,432,339 (entitledCONTINUOUS MOLDING OF FASTENER PRODUCTS WITH A MOLD BELT), etc.

In another variation depicted in FIG. 13, the substrate 310 mayterminate in the area occupied by the portion 315 of the polymericstructure 314. An example of this is depicted by broken line 309 in FIG.13. The line 309 may denote the edge of the substrate 310 during thetransfer process or the line 309 may denote a line along which thesubstrate 310 may be separated after the polymeric structure 314 istransferred to the surface 311.

In still another variation, the substrate 310 itself may include a loopstructure on the surface opposite that on which the polymeric structuresare located or within the areas on the same surface as the polymericstructures that are not occupied by the polymeric structures. As aresult, the composite web may provide a unitary fastener having bothstems, hooks, etc, and the complementary loop material needed forfastening.

FIG. 14 depicts yet another embodiment of a composite web manufacturedin accordance with the present invention. The composite web includes asubstrate 410 with opposing major surfaces 411 and 412. One featureillustrated in FIG. 14 is the two-sided nature of the polymericstructures located on the opposing major surfaces 411 and 412,respectively. Polymeric structure 414 is provided on major surface 411and polymeric structure 424 is provided on opposing major surface 412.Both polymeric structure 414 and polymeric structure 424 are exposed onopposite sides of the composite web.

The polymeric structures on opposing major surfaces are depicted asbeing in registration through the substrate 410. In other words, thepolymeric structure 414 is aligned with the polymeric structure 424 onthe opposite side of the substrate 410. Further, the polymeric structure414 is depicted as being substantially the same size as the polymericstructure 424 located on the opposite side of the substrate 410. Itshould, however, be understood that when a composite web havingpolymeric structures on both major surfaces is desired, the polymericstructures on the opposing surfaces may or may not be the same size asseen in FIG. 14. Also, it should be understood that the polymericstructures may or may not be in registration with each other through thesubstrate 410 as seen in FIG. 14.

The polymeric structures 414 and 424 may be envisioned as forming agrommet structure on the substrate 410. As a result, it may be desiredto provide an optional opening 404 through the substrate 410 as seen inFIG. 10. The opening may be formed by any suitable technique, e.g.,mechanical perforation with a tool, laser ablation, water or gas-jetcutting, etc.

Although not depicted, other variations in composite webs manufacturedaccording to the present invention may include two or more substrateslaminated together with one or more polymeric structures located betweenthe laminated substrates. Such laminated constructions may be useful,for example, to provide a cloth-like or softer feel or appearance,breathability, porosity, etc. on both sides of the composite web. Thisis in contrast to the composite webs in which the polymeric structuresare located on an exposed surface of the composite web. A laminatedcomposite web structure may also be used to provide different propertieson opposite sides of the composite web structure. For example, theporosity or other properties may differ between the differentsubstrates. Examples of such laminating processes may be described in,e.g., U.S. Patent Application Publication No. U.S. 2003/0087098 A1,filed 5 Nov. 2001 and titled COMPOSITE WEBS WITH REINFORCING POLYMERICREGIONS AND ELASTIC POLYMERIC REGIONS and U.S. Patent ApplicationPublication No. U.S. 2003/0084996 A1, filed 5 Nov. 2001 and titledMETHODS FOR PRODUCING COMPOSITE WEBS WITH REINFORCING DISCRETE POLYMERICREGIONS.

FIG. 15 depicts a web path and rolls in one system and method ofproviding polymeric structures 14 on one surface of a substrate 10 inaccordance with the principles of the present invention. The systemdepicted in FIG. 15 includes a substrate 10 that defines a web paththrough the system. The substrate 10 moves through the system in adownstream direction indicated by the rotation arrows on the variousrolls. After being unwound or otherwise provided from a supply (e.g.,the substrate 10 may be manufactured in-line with the system depicted inFIG. 15), the substrate 10 is directed into a transfer nip formedbetween a backup roll 20 and a forming tool 30.

Although the composite web may preferably be formed using a forming toolin the form of a roll in the illustrated embodiments, it should beunderstood that the forming tools of the present invention mayalternatively be provided in forms other than rolls, e.g., endlessbelts, etc. Furthermore, the forming tool (roll or otherwise) may bemanufactured by any suitable technique, e.g., a machining, etching,helically-wound rolls (such as in, e.g., U.S. Pat. No. 6,190,594 B1entitled TOOLING FOR ARTICLES WITH STRUCTURED SURFACES), stacked platetechnology, etc.

The process of providing polymeric structures 14 on the substrate 10includes delivering a supply of a molten thermoplastic composition tothe exterior surface 32 of forming roll 30 that includes a one or moredepressions formed in its exterior surface 32. The molten thermoplasticcomposition 41 is supplied to the exterior surface 32 of the formingroll 30 by a delivery apparatus in the form of a an extruder 40. Themolten thermoplastic composition is wiped or removed from the exteriorsurface 32 by a doctor blade 42 acting against the exterior surface 32of the forming roll 30. Although it may be desirable to remove all ofthe thermoplastic composition from the exterior surface 32 of theforming roll 30, some of the thermoplastic composition may remain on theexterior surface 32 after wiping by the doctor blade 42.

The doctor blade 42 is preferably heated to a temperature that is atleast the melt processing temperature of the thermoplastic composition.It may be preferred that the doctor blade temperature be the same as thetemperature of the molten thermoplastic composition 41 extruded by theextruder 40 or even higher.

The roll temperature of roll 30 is also preferably controlled in thesystems of the present invention. As discussed above, it is preferredthat the roll temperature be lower than the melt processing temperatureof the thermoplastic composition being deposited on the roll 30. Bycontrolling the roll temperature, various processing advantages may beobtained as discussed herein.

The extruder 40 in the depicted system preferably extrudes the moltenthermoplastic composition 41 into the interface of the doctor blade 42and the exterior surface 32 of the roll 30. In some instances, themolten thermoplastic composition 41 may flow down the doctor blade 42 tothe interface between the blade 42 and the roll 30.

The depressions formed in the exterior surface 32 of the forming roll 30preferably receive a portion of the molten thermoplastic compositionwhen the molten thermoplastic composition is deposited on the exteriorsurface 32 of the forming roll 30. Filling of the depressions by themolten thermoplastic composition may be enhanced by the wiping action ofthe doctor blade 42 on the exterior surface 32 of the forming roll 30.The flow rate of the molten thermoplastic composition 41 from theextruder may be controlled such that the volume of the moltenthermoplastic composition may preferably be equivalent to the volume ofthe depressions passing the doctor blade. That relationship may beadvantageous because it may prevent or reduce the accumulation ofthermoplastic composition behind the doctor blade 42. Accumulation ofthe thermoplastic composition behind the doctor blade 42 may bedetrimental because of the lower roll temperature, which can cause theviscosity of the thermoplastic composition to increase such that thedepressions cannot be filled properly.

FIG. 16 is an enlarged partial cross-sectional view depicting onerelationship between a doctor blade 42 and exterior surface 32 withdepressions 34 in a forming roll 30. The roll 30 rotates such that theexterior surface 32 is moving past the doctor blade 42 in the directionshown by the arrow. The molten thermoplastic composition 41 in thedepicted embodiment is incident on the upper surface of the doctor blade42 and flows down that surface towards the interface between the doctorblade 42 and the exterior surface 32 of the roll 30. Alternatively, themolten thermoplastic composition flow could be adjusted such that itflows directly into the interface between the doctor blade 42 and theroll 30.

As the depressions pass underneath the doctor blade 42, they arepreferably filled with the molten thermoplastic composition 41 as seenin FIG. 16. In the depicted embodiment, the flow of molten thermoplasticcomposition 41 is preferably adjusted such that it is equivalent to thevolume of the depressions 34 passing underneath the doctor blade 42. Theresult is that only a limited amount or none of the thermoplasticcomposition material accumulates at the interface of the roll 30 and thedoctor blade 42.

Achieving that result may involve controlling the temperature of theroll 30 along with one or more of the following: doctor bladetemperature, molten thermoplastic composition temperature, roll speed,flow rate of the molten thermoplastic composition, the pressure or forceexerted on the forming roll 30 by the doctor blade 42, etc.

Another optional feature depicted in FIG. 16 is that the moltenthermoplastic composition 41 is largely removed from the exteriorsurface 32 of the roll 30 by the doctor blade 42. As such, the moltenthermoplastic composition in the depressions 34 that have passed thedoctor blade 42 is limited to the depressions only. In contrast, FIG. 17depicts an alternative process in which a layer 143 of the moltenthermoplastic composition 141 remains on the exterior surface 132 of theroll 130 after the depressions have passed the doctor blade 142. Thatlayer 143 can be used to form the base films described in connectionwith FIGS. 2 and 3 above. Control over the formation of a base film inthe systems and methods of the present invention may be achieved byadjusting, e.g., roll temperature, doctor blade temperature, moltenthermoplastic composition temperature, roll speed, flow rate of themolten thermoplastic composition, the pressure or force exerted on theforming roll by the doctor blade, the gap (if any) between the doctorblade and the forming roll, the spacing between the depressions, thevolume of the depressions, etc.

Another optional feature depicted in connection with FIG. 17 is theaddition of a ridge 135 around at least a portion of the perimeter ofthe depressions 134. The ridge 135 is raised above the exterior surface132 of the roll 130. One potential advantage of the raised ridge 135 isthat it may facilitate removal of a base film from polymeric structureson a substrate by providing a thinner area of weakness around theperimeter of the polymeric structure.

Returning to FIG. 15, with the depressions at least partially filledwith the desired molten thermoplastic composition, the forming roll 30continues to rotate until the depressions and the molten thermoplasticcomposition they contain are forced into contact with the substrate 10against backup roll 20 at the transfer nip (i.e., the nip formed by theforming roll 30 and the backup roll 20). It is at this point thattransfer of the molten thermoplastic composition in the depressions tothe substrate 10 begins. By controlling the roll temperature to a pointbelow the melt processing temperature of the thermoplastic composition,the thermoplastic composition in the depressions may preferably releasecleanly from the depressions such that substantially all of thethermoplastic composition in the depressions is transferred to thesubstrate 10.

When a substrate 10 that includes one or more porous major surfaces onwhich the molten thermoplastic composition is deposited is used inconnection with the methods of the present invention, a mechanical bondmay preferably be formed by infiltration of the molten thermoplasticcomposition into the porous surface of the substrate 10. As used inconnection with the present invention, the term “porous” includes bothstructures that include voids formed therein, as well as structuresformed of a collection of fibers (e.g., woven, nonwoven or knit) thatallow for the penetration of molten thermoplastic compositions. If thesubstrate 10 is not porous but is made of a thermoplastic composition,attachment of the polymeric structures may be achieved by intermixing asdescribed herein.

The nip pressure between the forming roll 30 and the backup roll 20 ispreferably sufficient to result in attachment of the thermoplasticcomposition in the depressions of the roll 30 to the substrate 10. Ifthe substrate surface is porous, a portion of the thermoplasticcomposition in the polymeric structures infiltrates and/or encapsulatesa portion of the porous substrate 10 to improve attachment of thepolymeric structures to the substrate 10. Where the surface of thesubstrate 10 includes fibers (e.g., where the substrate 10 includeswoven, nonwoven, or knit materials on its major surfaces), it may bepreferred that the thermoplastic composition encapsulate all or aportion of at least some of the fibers on the surface of the substrate10 to improve attachment of the polymeric structures to the substrate10.

Under some conditions the molten thermoplastic composition in thedepressions 34 may completely permeate the substrate 10 if, e.g., thesubstrate 10 is porous throughout its thickness. In other instances,penetration of the molten thermoplastic composition may be limited tothe outer layer or layers of the substrate 10.

It should, however, be understood that although the outer surfaces ofthe substrate 10 may exhibit some porosity, that porosity may notnecessarily extend through the entire thickness of the substrate 10. Forexample, the substrate 10 may have a variety of different layers, withone of the layers being substantially non-porous. In anotheralternative, the overall thickness of the substrate 10 may render itnon-porous as a whole, even though the outer surfaces of the substrate10 exhibit some porosity as discussed above.

The backup roll 20 may possess a variety of different characteristicsdepending on the types of substrate materials and/or moltenthermoplastic compositions being processed. In some instances, theexterior of the backup roll 20 may be a rubber or other conformablematerial that conforms to the shape of the forming roll 30. If aconformable material such as rubber is used, it may, e.g., have adurometer of, e.g., about 10-90 Shore A.

One such variation at the transfer nip is depicted in the enlargedcross-sectional view of FIG. 18, in which a conformable backup roll 30is depicted as forcing a portion of the substrate 10 into the depression34 (and the thermoplastic composition 41 contained therein). If thesurface of the substrate 10 facing the depression 34 is porous, aportion of the molten thermoplastic composition 41 may be forced in theporous surface of the substrate 10. Forcing the substrate 10 into thedepression may be particularly beneficial if the depression 34 is notcompletely filled with the molten thermoplastic composition 41 toimprove the likelihood of contact between the substrate 10 and themolten thermoplastic composition 41.

Other backup rolls may also be used in connection with the presentinvention. For example, the backup roll may have mating protrusions thatact to force the substrate into the depressions. In another alternative,the backup roll may have a structured (as opposed to a smooth) surfacesuch that increased pressure is applied to the substrate 10 only wherethe backup roll has a raised structure. For example, the backup roll mayhave a corrugated surface or other wise include ribs, posts, etc. toachieve differential bonding of the polymeric structures formed in thedepressions to the substrate 10.

By controlling the temperature of the forming roll as discussed above,transfer of the thermoplastic composition 41 in the depression 34 may beenhanced because the cooler roll temperature preferably results infreezing or solidification of the thermoplastic composition directlyadjacent the surfaces of the depression 34, while an amount of thethermoplastic composition 41 that is furthest from the surfaces of thedepression 34 remains sufficiently molten to accomplish desiredattachment to the substrate 10. Release of the thermoplastic compositionfrom the depressions 34 and/or the exterior surface 32 of the roll 30may be enhanced if those surfaces are coated with low surface energymaterials (e.g., fluoroethylenes, etc.).

In addition to controlling the temperature of the forming roll, it mayalso be beneficial to control the temperature of the backup roll 20. Forexample, it may be desirable to heat or cool the surface of the backuproll 20 to a selected temperature.

Although the system and method depicted in FIG. 15 produces compositewebs with polymeric structures on only one major side thereof, polymericstructures may be provided on both major surfaces of the substrate inaccordance with the principles of the present invention. One example mayinclude, e.g., forming polymeric structures on one surface of each oftwo separate substrates, with the two substrates then being laminatedtogether to form a single substrate with polymeric structures on bothmajor surfaces (see, e.g., FIG. 14). Alternatively, a single substratemay be directed into a nip formed by two forming rolls, with each of theforming rolls depositing polymeric structures on both sides of the webessentially simultaneously.

Although FIG. 15 depicts the application of only one thermoplasticcomposition using the forming roll 30, it will be understood that two ormore different thermoplastic compositions may be applied to the exteriorsurface of the forming roll 30. FIG. 19 depicts a portion of one systemin which three molten thermoplastic compositions (in zones A, B, & C)are delivered to different portions of the surface of a forming roll 530that rotates about an axis 531. If extruders 540 a, 540 b and 540 c areused, the different thermoplastic compositions may be delivered in amanner such that molten thermoplastic compositions in the differentzones do not mix during processing.

The forming roll 530 also includes different sets of depressions 534 a,534 b, and 534 c over which the different molten thermoplasticcompositions may be applied. The depressions in the different zones onforming roll 530 are differently shaped, have different sizes, and havedifferent spacing. For example, the triangular depressions in zone C arearranged in an irregular, non-repeating pattern while the depressions inzones A & B are arranged in regular, repeating patterns.

With the system of FIG. 19, different sets of polymeric structures maybe formed on a single substrate or different substrates using differentthermoplastic compositions. As a result, the thermoplastic compositionsmay be selected for any of a number of different properties related tomanufacturing or end-use performance of the finished articles made usingthe composite webs.

FIG. 20 is a plan view of a portion of a forming roll 630 that may beused in connection with the present invention. The roll 630 includes anexterior surface 632 with a patterned depression 634 formed therein. Thedepression 634 may be, e.g., in the form of intersecting troughs suchthat a screen-like pattern is formed.

FIGS. 21 and 22 depict a composite web that may be manufactured usingthe forming tool 630 of FIG. 20, with FIG. 21 being a plan view of thearticle and FIG. 22 being a cross-sectional view of the composite webtaken along line 22-22 in FIG. 21. The polymeric structure 614 includessegments 616 that are attached to the surface 611 of the substrate 610(see, e.g., FIG. 22) and segments 615 that are not attached to thesurface 611 of the substrate 610. It may be preferred that the portions618 of the substrate 610 opposite the unattached segments 615 formarcuate channels spaced from the polymeric structure 614.

Also, although not depicted, all or portions of the polymeric structure614 may include surface features formed on the upper surface thereof (asdescribed in connection with, e.g., FIGS. 12 and 13).

The composite web of FIGS. 21 and 22 may be formed by, e.g.,transferring an elastomeric thermoplastic composition to the substrate610. The elastomeric thermoplastic composition may preferably form apolymeric structure 614 that exhibits elasticity. It may further bepreferred that the polymeric structure 614 exhibit differential bondingto the substrate 610 such that portions of the substrate 610 areattached more securely to the polymeric structure 614 than otherportions. For example, it may be preferred that the intersectionsbetween the various strands or segments of the polymeric structure 614be attached more securely than the intervening segments. These moresecure attachment points may be the result of a locally increased massof molten thermoplastic composition as discussed above in connectionwith FIGS. 6-13.

In addition, it may be preferred that the substrate 610 be manufacturedof a non-elastomeric material or an elastic material that has a yieldpoint below that of the elastomeric polymeric structure 614. Aftertransfer of the thermoplastic composition, the substrate 610 (with thepolymeric structure 614 formed thereon) can be stretched in thedirections of arrow 602 (see FIG. 21). The stretching is preferablysufficient to cause the substrate 610 to release from the polymericstructure 614 along at least some of the segments 615 and result in thegathers or puckers seen in FIG. 22.

The stretching is also preferably sufficient to cause permanentelongation of the substrate 610 that provides the additional lengthneeded to form the arcuate portions 618 after the stretching force isreleased. The polymeric structure 614 itself may experience somepermanent elongation as a result of the stretching, but its magnitudewill be below that of the substrate such that the arcuate portions 618are formed as seen in FIG. 22.

Although the substrate 610 is preferably extensible, a nonextensiblesubstrate 610 can be made extensible by, e.g., providing slits in thesubstrate. The slits may preferably be spanned by the elastomericpolymeric structure 614. Some exemplary slitting processes to provide orimprove extensibility of a substrate are described in InternationalPublication No. WO 96/10481 (Abuto et al.). Other techniques may also beused to provide or improve the extensibility of substrates used inconnection with the present invention. For example, the mechanicalstretching processes described in U.S. Pat. No. 4,223,059 (Schwarz) andU.S. Pat. No. 5,167,897 (Weber et al.) may be used to provide or improveextensibility.

In addition to stretching in direction 602, it may also be beneficial tostretch the composite web in the direction of arrow 603 in FIG. 21. Theresulting two-dimensional stretching may cause the substrate topermanently elongate in both directions, with the substrate formingpillow-like structures between the intersection points in the polymericstructure 614.

As another alternative to obtain the composite web of FIG. 22, it may bepossible to use a substrate 610 that is, itself, elastic. Such anelastic substrate may be stretched in the machine direction and/or oneor more different directions before the polymeric structure 614 istransferred thereto. After formation of the polymeric structures on thestretched elastic substrate 610, the substrate 610 may be allowed torelax such that the arcuate portions 618 are formed.

Composite webs such as those depicted in FIGS. 21 and 22 may be usefulas, e.g., elastic components for disposable articles, diapers,incontinence devices, gowns, clothing, filtration devices, etc.

As an alternative to the patterned depression of FIG. 20, the polymericstructure 614 of FIGS. 21 and 22 may be formed by the system and methoddepicted in FIG. 23. The system includes a forming roll 730 with anexterior surface 732. A series of depressions 734 are formed in theexterior surface 732 of the forming roll 730. One feature illustrated inFIG. 23 is that the doctor blade 742 includes notches 750 such that,after wiping. a portion of the molten thermoplastic composition passesthrough the interface between the doctor blade 742 and the roll 730 andremains on the exterior surface 732 of the roll 730 in a series ofstrands 752 that extend around a portion of the circumference of theroll 730. In that manner, the cross-hatched pattern of FIGS. 21 and 22can be obtained without requiring a patterned depression thatcorresponds precisely to the shape of the polymeric structure 614.

FIG. 24 depicts yet another system and method that may be used inconnection with the present invention. The system includes a formingroll 830 with an exterior surface 832 and depressions 834 formedtherein. In a manner similar to that described in connection with FIGS.16 and 17, the system includes a doctor blade 842 that functions as anextrusion die in addition to a doctor blade. The doctor blade includesan orifice 843 from which a first molten thermoplastic composition 841is extruded. The molten thermoplastic composition 841 flows down theface 844 of the doctor block 842 until it reaches the interface with theroll 830. At that point, the molten thermoplastic composition 841 fillsthe depressions 834.

In addition to the extrusion of molten thermoplastic composition 841,the doctor block 842 of FIG. 24 also includes an optional orifice 863through which a second molten thermoplastic composition 861 flows ontothe exterior surface 832 of the forming roll 830. The second moltenthermoplastic composition 861 may preferably be provided in the form ofgenerally continuous strands 860 as the roll 830 rotates in thedirection of the depicted arrow. The second molten thermoplasticcomposition 861 may be the same as or different than the first moltenthermoplastic composition 841.

Other variations include that the depressions 834 may be limited in sizeor they may extend across the roll face (as seen in, e.g., FIG. 23). Ifthe depressions 834 extend across the roll face as seen in FIG. 23, thenthe system of FIG. 24 provides another alternative system and methodform forming a polymeric structure such as that seen in FIGS. 21 and 22.One potential advantage of the system of FIG. 24 is that the moltenthermoplastic compositions 841 and 861 may be different to supply, e.g.,different properties to the resulting composite web.

Regardless of the method used to form the polymeric structure 614 ofFIG. 21, the polymeric structure 614 may exhibit differential bonding asdescribed herein due to the increased mass of thermoplastic compositionat the intersections between the segments 615 and 616. Those areas ofincreased mass may form bonded areas 617 (see FIG. 21) that are securelyattached to the substrate 610, while the segments 615 and 616 may or maynot be securely attached to the substrate 610, that is, they may bedetached areas. The detached areas may be lightly attached to thesubstrate immediately after transfer of the polymeric structure thereto,but become detached from the substrate 610 after stretching or otherphysical manipulation (e.g., bending, flexing, etc.). Alternatively, thedetached areas may be formed by thermoplastic composition that fallsbelow the melt processing temperature before contacting the substrate610 such that no bond is formed during transfer of the polymer structure614 to the substrate.

FIGS. 25A-25E depict alternate composite web constructions in which twodifferent thermoplastic compositions in different polymeric structuresare transferred to a substrate or in which the same thermoplasticcomposition is applied in two different structures on a substrate. Theconstructions are provided to illustrate that the transfer methods ofthe present invention can be used to provide different polymericstructures that overlap each other on the same area of the substrate insome manner. In one example, one of the polymeric structures may exhibitelastic behavior while the other does not.

Although only two different structures are depicted in each figure, itwill be understood that more than two different polymeric structurescould be provided. Also, surface features such as those depicted in FIG.13 may be provided on the polymeric structures if so desired.Furthermore, although only one set of polymeric structures is depictedin each figure, each composite wed may include a plurality of the sameor different polymeric structures. The different polymeric structuresmay, for example, be applied by successive stations such as the stationdepicted in FIG. 15.

FIG. 25A depicts a first polymeric structure 914 a on the substrate 910a and a second polymeric structure 924 a that is located on both thesubstrate 910 a and the first polymeric structure 914 a. The secondpolymeric structure 924 a may be attached to the first polymericstructure 914 a or not as desired.

FIG. 25B depicts a first polymeric structure 914 b on the substrate 910b and a second polymeric structure 924 b that is located on both thesubstrate 910 b and over the first polymeric structure 914 b. The secondpolymeric structure 924 b is depicted as attached to the upper surfaceof the first polymeric structure 914 b.

FIG. 25C depicts a first polymeric structure 914 c on the substrate 910c and a second polymeric structure 924 c that is attached to thesubstrate 910 c in areas 926 c and that extends over the first polymericstructure 914 c. The second polymeric structure 924 c is depicted asdetached from the upper surface of the first polymeric structure 914 c.

FIG. 25D depicts a first polymeric structure 914 d attached directly tothe substrate 910 d and a second polymeric structure 924 d that islocated on only the first polymeric structure 914 d, that is, within thefootprint of the first polymeric structure 914 d on the substrate 910 d.The second polymeric structure 924 d is depicted as attached to theupper surface of the first polymeric structure 914 d.

FIG. 25E depicts a first polymeric structure 914 e and a secondpolymeric structure 924 e, both attached to the substrate. Bothstructures include detached portions that are generally located withinarea 928 e in FIG. 25E. The first polymeric structure 914 e includes aportion that is attached to the substrate and a portion that is detachedfrom the substrate. The detached portion of the first polymericstructure 914 e is generally located under a portion of the secondpolymeric structure 924 e. The second polymeric structure 924 e alsoincludes a portion that is attached to the substrate and a portion thatis detached from the substrate. The detached portion of the secondpolymeric structure 924 e is generally located over the first polymericstructure 914 e.

In addition to the deposition of nonelastic or elastic thermoplasticpolymeric structures on a substrate, it is also contemplated thatadditional materials can be coated onto a major surface of the substrateusing known methods. Such materials could be, for example adhesives, asdescribed in, e.g., U.S. Pat. No. 5,019,071 (Bany et al.); U.S. Pat. No.5,028,646 (Miller et al.); and U.S. Pat. No. 5,300,057 (Miller et al.);or cohesives as described in, e.g. U.S. Pat. No. 5,389,438 (Miller etal.) and U.S. Pat. No. 6,261,278 (Chen et al.).

Closure Elements and Systems

Although there exist in the art many types of structures that provideconnections between substrates, and many systems of elements thatprovide closures, there continues to be a need for improved closureelements and systems. The polymeric structures and composite websdescribed herein may be used to provide closure elements and systems.For example, as discussed above, polymeric structures such as depictedin FIG. 13, provided by a forming tool such as depicted in FIG. 12, mayprovide surface features 352 useful in mechanical fastening systems.Additionally, certain composite web constructions, such as that depictedin FIG. 25E, may provide mechanical fastening by, for example, securingmaterials, such as fibers, loops, etc., between the detached portion ofthe polymeric structure 914 e, to provide a closed orientation. Somefurther exemplary closure elements and systems are described below;however, it is understood that closure elements and systems ascontemplated by the present invention are not to be limited to theembodiments described herein.

Composite webs including thermoplastic polymeric structures attached tosubstrates as described herein may advantageously provide closureelements and systems including, but not limited to, low profile in-planeclosure elements and systems, with the polymeric structures providingthe closure elements. Such elements may, for example, provide closure byengaging with fibers of a loop material, by engaging with a loop-likematerial provided by extrusion processes described herein, by aself-mating design as described herein, etc.

Closure elements and closure systems of the present invention maytypically include a composite web provided as disclosed herein, whereinthe composite web includes a substrate with a first major surface andone or more polymeric structures of a thermoplastic composition attachedto the first major surface of the substrate. Such polymeric structuresmay provide closure elements of the closure systems of the presentinvention. In the present systems, each polymeric structure of the oneor more polymeric structures occupies an area of the first major surfaceof the substrate. Such area occupied by the polymeric structurepreferably includes a bonded area, or attachment area, in which thethermoplastic composition of the polymeric structure is attached to thefirst major surface. The area occupied by the polymeric structurefurther includes at least one detached area in which the polymericstructure is not attached to the first major surface of the substrate.

The composite webs of the invention that provide closure elements andclosure systems may optionally include materials such as have beenalready disclosed herein. For example, the first major surface of thesubstrate may include polymeric material having a melt processingtemperature at or below a melt processing temperature of thethermoplastic composition of the one or more polymeric structures. Thecomposite web may also include a polymeric material in the form of apolymeric film.

Additionally, attachment of the polymeric structures to form closureelements and systems of the invention may include structures and methodsdisclosed herein. For example, the invention may include a composite webincluding a substrate having a first major surface that includes aporous surface, and wherein the thermoplastic composition in the bondedareas of the one or more polymeric structures infiltrates into theporous first major surface of the substrate to a depth of, e.g., atleast 50% of a thickness of a porous portion of the substrate. The firstmajor surface of the substrate may, additionally, include fibers,preferably polymeric fibers, having a melt processing temperature at orbelow a melt processing temperature of the thermoplastic composition ofthe one or more polymeric structures and wherein at least a portion ofat least some of the fibers are encapsulated in the thermoplasticcomposition within the bonded area. Embodiments further includecomposite webs providing closure element and systems wherein eachpolymeric structure, or a portion thereof, of the one or more polymericstructures includes a one piece, completely integral mass of thethermoplastic composition.

It is further contemplated that the composite webs of the invention alsomay include embodiments wherein the thermoplastic composition of the oneor more polymeric structures includes one or more elastomeric polymericcomponents such that the one or more polymeric structures exhibitelastic behavior. Additionally, the composite webs of the invention mayinclude at least one of the one or more polymeric structures which hasan upper surface facing away from the first major surface of thesubstrate, and wherein the upper surface includes surface features, suchas stems or pins protruding therefrom, formed thereon.

The methods of providing composite webs, as previously disclosed herein,also serve to provide methods for providing closure elements and systemsof the invention. For example, a method of attaching articles, such asthe polymeric structures attached to substrates as discussed above iscontemplated, wherein the method includes providing a composite web asdisclosed herein which includes, for example, a substrate having a firstmajor surface and one or more polymeric structures of a thermoplasticcomposition attached to the first major surface of the substrate,wherein each polymeric structure of the one or more polymeric structuresoccupies an area of the first major surface of the substrate, and thearea occupied by the one or more polymeric structures includes a bondedarea, in which the thermoplastic composition of the polymeric structureis attached to the first major surface in any suitable manner and theoccupied area further includes a detached area in which the polymericstructure is not attached to the first major surface of the substrate.

Substrates, thermoplastic materials, methods of forming the compositewebs including thermoplastic polymeric structures, and shape anddisposition on the webs of the polymeric structures may be any describedherein that are suitable to provide closure elements and systems.Additionally, the polymeric structure closure elements may be attachedto the substrate in any suitable manner described herein. Usefultechniques of attaching closure elements include, for example, preparingclosure elements using a cell in a gravure roll that provides a thickerregion that will retain sufficient heat to fuse to a compatiblesubstrate. One example of such a method is described herein inconnection with FIGS. 12 and 15. If the substrate surface includes afiber based material, such as a nonwoven or woven material, this regionmay flow into the substrate and encapsulate the fibers, thereby usingthe various depths of the gravure cells to achieve bonded and detachedareas. Another potential method may involve an extrusion process whereingrooves are cut into a doctor blade to yield zones of molten polymerdeposited on the gravure roll in an overlapping configuration with thegravure cells. One example of such a method is described herein inconnection with FIG. 23. This provides thicker regions of polymer thatretain sufficient heat and fluidity to bond to substrates as well as theclosure elements.

FIGS. 26 a-26 b depict one composite web construction according to thepresent invention including oval shaped closure elements 26 a withdetached end areas 26 b. FIG. 26 a shows a plan view of a substrateincluding the oval shaped closure elements 26 a attached to the firstmajor surface of the substrate 26 c. The closure elements 26 a areattached to the substrate in a bonded area 26 d that extends between thedetached areas 26 b of the oval shaped closure elements 26 a.Alternatively, it is appreciated that the oval shaped closure elements26 a may be attached to the first major surface of the substrate 26 c asseparate, discrete closure elements that are not connected to each otherby bonded area 26 d. Furthermore, the oval shaped closure elements 26 amay be attached to the substrate 26 c in any one of multipleconfigurations, e.g., in a regular pattern, in an irregular pattern, ina random pattern, closure elements attached over the entire surface ofthe substrate 26 c, or only on a portion of the substrate 26 c, etc.

FIG. 26 b is a cross-sectional view of a single oval shaped element 26a, taken along the line 26 b-26 b shown in FIG. 26 a. FIG. 26 b depictsthe center section of the closure element 26 a, which may preferablypenetrate into the substrate at attachment point 26 e, and two portions26 b that are detached from the substrate 26 c. The portions 26 b of thedepicted closure element 26 a are cantilevered over and aligned with thefirst major surface of the substrate 26 c.

The term “cantilevered” (and variations thereof) is understood herein tomean a member or a portion of a closure element that is projected overthe substrate, wherein the member or portion of the closure element issupported at only one end. A detached and cantilevered area of a closureelement may have an orientation that is aligned with the first majorportion of the substrate as depicted in, e.g., FIG. 26 b. That is, thedetached and cantilevered portions 26 b of closure element 26 a may besubstantially parallel to the surface of the substrate 26 c.Alternatively, the detached and cantilevered portions 26 b may beoriented in such a manner that the member is not substantially parallelto the surface of the substrate. Use of the term “cantilevered” (andvariations thereof) is not meant to imply that the cantilevered portionof any polymeric structure is not in contact with the substrate surfaceabove which it is cantilevered. Rather, in some instances thecantilevered portion may be in contact with the underlying substratesurface (but not attached thereto) and in other instances, thecantilevered portion may not be in contact with the underlying substratesurface.

The cross-sectional view, as depicted in FIG. 26 b, shows an oval shapedpolymeric closure element 26 a occupying an area of the surface of thefirst major surface of the substrate 26 c, wherein the element includesa bonded area 26 e attached to the surface of the substrate 26 c anddetached area 26 b that is not attached to the substrate 26 c.Furthermore, in the detached area 26 b, the depicted polymeric closureelement is cantilevered over and is aligned with the first major surfaceof the substrate 26 c.

Closure elements such as those depicted in FIG. 26 may preferably becapable of engaging with loop material, when the closure elements areappropriately sized. Such closure elements may typically possess shearresistance, i.e., the ability to limit sliding motion between twosubstrates, but the closure elements may not exhibit strong peel forces.To prepare closure elements of the invention having both increased shearresistance, and increased peel characteristics, the polymeric closureelements may include barb structures.

One example of polymeric closure elements including barb structures isdepicted in FIGS. 27 a-27 b. FIG. 27 a is a plan view of a substrateincluding closure elements 27 a including barb structures 27 f. Theclosure elements 27 a include at least one detached area 27 b and areattached to a first major surface of a substrate 27 c at a bonded area27 e. The detached areas 27 b are cantilevered over the first majorsurface of the substrate 27 c and may be characterized as stems having afree end supported above the first major surface of the substrate 27 c.

The closure elements 27 a are connected to each other by bonded areas 27d that extend between the closure elements 27 a. Alternatively, it isappreciated that the closure elements 27 a may be attached to the firstmajor surface of the substrate 27 c as separate and discrete elements,i.e., without interconnection by bonded areas 27 d. Furthermore, theclosure elements 27 a may be attached to the substrate 27 c in any oneof multiple configurations, e.g., in a regular pattern, in an irregularpattern, in a random pattern, closure elements attached over the entiresurface of the substrate 27 c, or only on a portion of the substrate 27c, etc.

As depicted in FIG. 27 a, each of the closure elements 27 a includes abarb structure 27 f on the detached area 27 b. Alternatively, it isenvisioned that some of the closure elements 27 a may include barbstructures 27 f on only some of the detached areas 27 b. Furthermore,certain embodiments may include closure elements 27 a having no barbstructures 27 f. As depicted in FIG. 27 a, the closure elements 27 aeach include four distinct detached areas 27 b. Alternatively, some orall of the closure elements 27 a may include either more or fewer thanfour distinct detached areas 27 b.

Also, the barb structure 27 f is depicted proximate a distal end of thedetached area 27 b from the bonded area 27 e. It is understood, however,that the barb structure 27 f may be located at any point along thedetached area 27 b, that the position of the barb structure 27 f mayvary from one detached area 27 b to another, and that the position ofthe barb structure 27 f may vary from one closure element 27 a toanother.

As understood herein, a barb is a structure extending outward in a firstdirection and including a projection extending substantially in a seconddirection ranging from perpendicular to the first direction tosubstantially opposite the first direction. Such elements may be wellsuited to engaging fibers of a loop material, for example, to provideclosure elements having increase peel and shear characteristics, ascompared with closure elements that do not include barbs.

Additionally, closure elements 27 a may include detached areas 27 b thatare cantilevered as depicted in FIG. 27 b. Such cantilevered anddetached areas 27 b may or may not be aligned with the first majorsurface of the substrate 27 c. FIG. 27 b is a cross-sectional view of aclosure element 27 a of FIG. 27 a taken along line 27 b-27 b depicted inFIG. 27 a. In this embodiment, the detached areas 27 b of element 27 aare cantilevered and are not aligned with the substrate surface 27 c,instead being inclined away from the surface of substrate 27 c.Providing detached areas 27 b that are not aligned with the majorsurface of the substrate 27 c may require additional processing beyondformation of the closure elements 27 a using a tool roll as describedherein. For example, the detached areas 27 b may need to be deformedfrom their shape as formed by, e.g., manipulating the detached areas 27b using counter-rotating rolls, brushes, a vacuum assembly, etc. Inanother example, the substrate 27 c may be directed over a sharp edgeimmediately after forming the closure elements 27 a.

FIGS. 28 a-28 c show a further embodiment of the composite webs of theinvention having closure elements including barbs. FIG. 28 a is a planview of a substrate including a first major surface 28 c with separateand discrete closure elements 28 a attached thereto. The closureelements 28 a include detached areas 28 b with barb structures 28 f. Inthe view shown in FIG. 28 a, the closure elements 28 a are regularlyspaced over the surface of the substrate 28 c. However, as described inconnection with the embodiment depicted in FIG. 27 a, the closureelements 28 a may be attached to the substrate 28 c in any one ofmultiple configurations, e.g., in a regular pattern, in an irregularpattern, in a random pattern, closure elements attached over the entiresurface 28 c of the substrate, or only on a portion of the substrate 28c, etc. Each of the elements 28 a of FIG. 28 a, one of which is shownenlarged in FIG. 28 b, include a barb structure 28 f on the detachedareas 28 b. Alternatively, it is envisioned that some of the closureelements 28 a may include barb structures 28 f on only some of thedetached areas 28 b. Furthermore, certain embodiments may includeclosure elements 28 a having no barb structures 28 f. As depicted inFIGS. 28 a and 28 b, the closure elements 28 a each include fourdistinct detached areas 28 b. Alternatively, some or all of the closureelements 28 a may include either more or fewer than four distinctdetached areas 28 b. Also, as depicted in FIG. 28 b, the barb structure28 f is depicted at a distal end of the detached area 28 b relative tothe bonded area 28 e. It is understood, however, that the barb structure28 f may be located at any point along the detached area 28 b, and thatthe position of the barb structure 28 f may vary from one detached area28 b to another, from one closure element 28 a to another, etc.

The composite webs of the present invention may be adaptable to variousspecific closure requirements, depending on the shape and size of theclosure element required. FIGS. 29 and 30, for example, show certainadditional contemplated embodiments of the composite webs of theinvention, including various shapes of closure elements that may serveany one of a number of various requirements.

FIG. 29A shows a plan view of a substrate including a first majorsurface 29 c and further including discrete closure elements 29 aattached thereto at bonded areas 29 e (see FIG. 29B). In thisembodiment, the closure elements 29 a include at least one detached area29 b on only one side of the bonded area 29 e of the element. Thedetached area 29 b may include a single distinct area, as in a tab, orit may include more than one distinct member, as depicted in FIG. 29B.

In the view shown in FIG. 29A, the closure elements 29 a are regularlyspaced in a regular pattern over the surface of the substrate 29 c.However, as described in connection with, for example, the embodimentdepicted in FIG. 27 a, the closure elements 29 a may be attached to thesubstrate 29 c in any one of multiple configurations, e.g., in a regularpattern, in an irregular pattern, in a random pattern, closure elementsattached over the entire surface of the substrate 29 c, or only on aportion of the substrate 29 c, etc.

Furthermore, as depicted in FIG. 29C, the closure elements 29 a, may beconnected to each other by a bonded area 29 d that extends between thebonded areas 29 e of the closure elements 29 a, such as described inconnection with the embodiments shown in FIGS. 26 and 27.

As shown in FIG. 30, it is further contemplated that the closureelements of the present invention may include multiple detached areas onmultiple sides of the bonded area of the closure element, depending onthe closure requirements and any physical constraints that may bepresent. For example, the closure element 30 a of FIG. 30 includes eightdistinct detached areas 30 b extending from bonded area 30 c. Closureelements of the invention may include more or fewer distinct detachedareas of various shapes and sizes, as required.

FIGS. 31 a-31 b depict a further embodiment of a closure system on acomposite web of the present invention. This embodiment includes closureelements having thermoplastic polymeric structures including flexibledetached areas, providing a spring-type engaging member. FIG. 31 a is aplan view of a first major surface of a substrate 31 c including adiscrete closure element 31 a having a detached area 31 b that includesa thermoplastic polymeric structure providing a spring-type engagingmember 31 j. In this embodiment, the discrete closure element 31 aincludes a bonded area 31 e that includes a base in which thethermoplastic polymeric structure is attached to the substrate surface31 c and a detached area 31 b on one side of the bonded area 31 e thatincludes one or more cantilevered members in the detached area 31 b. Thecantilevered members of the detached area 31 b are preferably flexibleand, further, may include barbs 31 f. Additionally, the cantileveredmembers may either be aligned with the surface of the substrate 31 c, ormay be inclined either toward or away from the surface of the substrate31 c, depending on the closure requirements.

In addition to the closure element depicted in FIG. 31 a, the closuresystem further includes, as depicted in FIG. 31 b, a complementarysubstrate 31 k including one or more openings 31 m. The one or moreopenings 31 m in the complementary substrate 31 k may be of any shapesuch as, for example, a round hole, an oval-shaped hole, arectangular-shaped hole, a slit, etc., so long as the opening 31 m iscapable of receiving the one or more thermoplastic polymeric structuresthat form the spring-type engaging member 31 j of closure element 31 a,such that when the spring-type engaging member 31 j is located withinthe one or more openings 31 m of the complementary substrate 31 k, themovement of the complementary substrate 31 m and the movement of thesubstrate 31 c on which the closure element 31 a is attached, relativeto each other, is restricted.

FIG. 31 b, for example, shows the spring-type engaging member 31 j ofFIG. 31 a in an engaged orientation with a complementary slotted opening31 m in the complementary substrate 31 k, which provides a receivingmember for the spring-type engaging member 31 j. Another complementarysurface suitable for engaging the closure elements of FIG. 31 a mayinclude, for example openings formed by fiber loops.

FIGS. 32 a and 32 b show another contemplated embodiment of theinvention, including a composite web having a first major surface of thesubstrate that includes raised portions and surrounding valleys. Theraised portions may include, for example, ridges (as shown), discretepins, etc. As depicted in FIG. 32 a, the first major surface of thesubstrate 32 c may include raised portions 32 n, and depressions orvalleys 32 p between the raised portions 32 n. While FIG. 32 a showsraised portions 32 n having uniform heights, h, from the surface of thevalleys 32 p, it is understood that embodiments of the invention mayalso include raised portions 32 n having non-uniform heights and raisedportions having surfaces 32 o which are not substantially parallel tothe surface of the surrounding valleys 32 p. Such structures includingcomposite webs as depicted in FIG. 32 a may optionally be formed asdescribed and with a tool as described in the embodiments disclosed inconnection with, for example, FIGS. 6 and 7 above.

FIG. 32 is a view of the structure of FIG. 32 a, further includingpolymeric structures, 32 r attached to the raised portions 32 n. Thepolymeric structures 32 r may be attached to the raised portions 32 n inany appropriate manner, including any manner of bonding or attachmentdiscussed herein. Furthermore, the polymeric structures 32 r may includea closure element, including, but not limited to, a closure element ofany configuration disclosed herein. Additionally, while FIG. 32 b showsan embodiment wherein a polymeric structure 32 r is attached to eachraised portion 32 n, it will be understood that the inventioncontemplates embodiments wherein not all of the raised portions 32 ninclude polymeric structures 32 r attached thereto.

Further, the polymeric structures may be attached to the raised portions32 n of the substrate surface 32 c in, e.g., a regular pattern, anirregular pattern, a random pattern, etc. Furthermore, the polymericstructures 32 r may be attached to raised portions 32 r having a surface32 o that is not substantially parallel to the surface of thesurrounding valleys 32 p.

FIGS. 33 a and 33 b depict a closure system that provides a self-matingsystem when in a closed configuration. FIG. 33 a shows a first closureelement 33 a attached to a substrate 33 c. The closure element 33 aincludes a bonded area 33 e and a detached area 33 b on one side of thebonded area 33 e. The detached area 33 b includes a single member 33 sthat is cantilevered over and is, preferably, aligned with, the firstmajor surface of the substrate 33 c, such that a cantilevered tabstructure is formed in the detached area 33 b supported above the firstmajor surface of the substrate 33 c.

The closure element 33 a may preferably be shaped to form a pocket thatis bounded on one side by the substrate 33 c and on an opposing side bythe detached area 33 b. Movement of any member in the pocket to the leftalong the x-axis is prevented by the bonded area 33 e. Likewise, for amember completely inserted into the pocket, movement in either directionalong the y-axis is similarly restrained by the bonded area 33 e(because the end of the member proximate the bonded area 33 e wouldcontact the bonded area 33 e).

FIG. 33 b is a cross-sectional view of FIG. 33 a when mated with acomplementary second closure element 33 a′, taken along line 33 b-33 bof FIG. 33 a. The second closure element 33 a′ is attached to a firstmajor surface of a substrate 33 c′ and includes a detached area 33 b′and a bonded area 33 e′. The detached area 33 b′ provides a cantileveredtab structure, and the bonded area 33 e′ forms a second pocket in asimilar manner as the first pocket formed by the first closure element33 a. As depicted in FIG. 33 b, when in a closed configuration, thecantilevered tab of the first closure element 33 a is preferably locatedin the second pocket of the second closure element 33 a′, and thecantilevered tab of the second closure element 33 a′ is preferablylocated in the first pocket of the first closure element 33 a, thusproviding a closure system wherein the closure elements 33 a and 33 a′are engaged in a self-mating orientation.

The bonded area of the thermoplastic structure of either the firstclosure element, the second closure element, or both closure elements,may take any convenient shape, such as a box shape bonded area or aU-shape bonded area that assists in formation of a pocket. Furthermore,the cantilevered tab of the first closure element may be at leastpartially or substantially completely located within the second pocket,or the cantilevered tab of the second closure element may be at leastpartially or substantially completely located within the first pocketwhen the closure elements include, for example, a U-shaped bonded areaand when the closure system is in a closed configuration.

Additionally, while the closure system of FIG. 33 depicts a closuresystem wherein the closure elements both having the same elongated eggshape, the present invention also contemplates closure systems whereinthe closure elements are of various shapes and sizes, and wherein thefirst closure element and the second closure element do not necessarilyhave the same shape and bonding configuration, so long as the elementsprovide the required self-mating closure system when oriented in aclosed configuration.

EXAMPLES

The following examples are provided to enhance understanding of thepresent invention. The examples are not intended to limit the scope ofthe invention.

Example 1

A composite web was produced using a system similar to that shown inFIG. 15. A 40 mm diameter twin screw extruder fitted with a gear pumpwas used to deliver a molten polypropylene polymer (7C05N, Huntsman) ata melt temperature of approximately 246° C. to a die. The die waspositioned such that a film of molten polymer was extruded verticallydownward into the interface region of a heated doctor blade and a cooledforming roll.

The doctor blade was forced against the forming roll with a pressure of93 pounds per lineal inch (163 Newtons per lineal cm) (a pressure whichallowed the molten polymer to create a gap between the blade and theroll which defined the thickness of the base film). The doctor blade wasmaintained at a temperature of 246° C. and the forming roll wasmaintained at a temperature of 30° C. by circulating cooled oil throughthe interior of the roll.

The exterior surface of the forming roll was machined using a computercontrolled milling machine to have a series of elongated elliptical orring-shaped depressions with center islands, similar in shape to thedepressions shown in FIG. 10. The depressions, however, had a constantdepth. There were eight (8) depressions around the periphery of theroll. The depressions were elliptical in shape 8.825 cm long and 2.00 cmin width at the widest area. The long axis of each ellipse was orientedat an angle of 18 degrees to the machine direction (downweb). Theellipses were arranged with a center to center spacing of 12.1 cm. Theelliptical depressions had a maximum depth of 0.80 mm around the entireellipse and the sides of these depressions had a radius of 0.80 mm.

The rotation of the forming roll caused the doctor blade to wipe themolten polymer into these depressions while also allowing the formationof a base film layer (as shown in FIG. 17). After the wiping action ofthe doctor blade, the forming roll continued to rotate until the wipedpolymer was forced into contact with a polypropylene nonwoven substrate(Product C0075 Style 3320 with a basis weight of 27 grams per squaremeter (gsm) from BBA Nonwovens) against a conformable backup roll (witha durometer of 75 Shore A) using a nip pressure of 14 pounds per linealinch (25 Newtons/lineal cm).

A mechanical bond of the polymer in the elliptical depressions and thenonwoven substrate was achieved while no such bond was created betweenthe base film and the substrate. The polymer, both that forming the basefilm and that forming the elliptical features released cleanly andessentially completely from the surface of the forming roll when thesubstrate was directed away from the forming roll. The thickness of thebase film formed was 0.051 mm and the thickness of the ellipticalregions (measuring both the substrate and the elliptical region) was0.83 mm.

Example 2

A composite web was produced using a system similar to that shown inFIG. 15. A 40 mm diameter twin screw extruder fitted with a gear pumpwas used to deliver a molten polymer consisting of astyrene-ethylenebutylene-styrene block copolymer (KRATON G-1657) at amelt temperature of approximately 246° C. to a die. The die waspositioned such that a film of molten polymer was extruded verticallydownward into the interface region of a heated doctor blade and a cooledforming roll. The doctor blade was maintained at a temperature of 246°C. and the forming roll was maintained at a temperature of 30° C. bycirculating cooled oil through the interior of the roll. The doctorblade was held against the forming roll with a pressure of 450 poundsper lineal inch (788 Newtons/lineal cm).

The exterior surface of the forming roll was machined using a computercontrolled milling machine to have a series of six (6) different areasarranged around the periphery of the roll. Each of these areas includeda series of cross-direction (CD) grooves (depressions) running in thecross-machine direction (parallel to the axis of the forming roll). Eachof the six patterns had 30 CD grooves, each of which was 9 cm in length(in direction parallel to roll axis).

Among the six patterns, Area 1 was machined with CD grooves 1.241 mmwide, 0.2769 mm in depth and with center to center spacing between thegrooves (measured in the machine-direction, i.e., perpendicular to thecross-direction grooves) of 4.033 mm. Area 2 included CD grooves 1.695mm wide, 0.1727 mm in depth and with center to center spacing of 4.033mm. Area 3 included CD grooves 1.645 mm wide, 0.2007 mm in depth, andwith center to center spacing of 4.033 mm Area 4 included CD grooves1.531 mm wide, 0.2261 mm in depth, and with center to center spacing of4.033 mm. Area 5 included CD grooves parallel to the roll axis 2.387 mmwide, 0.3023 mm in depth, and with center to center spacing of 4.033 mm.Area 6 included CD grooves 2.195 mm wide, 0.3531 mm in depth, and withcenter to center spacing of 4.033 mm.

In addition to the CD grooves formed in the roll, the doctor blade wasmachined to include fifteen (15) notches such that fifteen (15) strandsof polymer were formed in the machine-direction (MD) on the exteriorsurface of the roll (as seen in FIG. 23). The notches were formed in thedoctor blade as grooves (0.135 mm wide by 0.381 mm deep) with a centerto center spacing measured in the cross-machine direction of 6.30 mm.

The polymer (KRATON G-1657) was transferred to a nonwoven polypropylenesubstrate (Product C0075 Style 3320 with a basis weight of 27 gsm fromBBA Nonwovens) at a nip formed with a conformable backup roll (a steelcore with a rubber cover having a durometer of 75 Shore A). The core ofthe backup roll was chilled by circulating water at a temperature of 5°C. The pressure exerted on the nip between the forming roll and thebackup roll was 14 pounds per lineal inch (25 Newtons/lineal cm). Thepolymer in the grooves and on the surface of the roll released cleanlyand essentially completely from the surface of the forming roll when thesubstrate was removed from the forming roll (as shown in FIG. 15).

The amount of polymer transferred within each of the six patterns showeddifferent levels of penetration into the substrate. To illustrate this,the area of the resultant composite web that corresponded to the patternof Area 3 exhibited a strong bond between the polymer and the substrateonly in the areas where the MD strands (formed by the notched doctorblade) crossed the CD strands (formed by the polymer in the CD grooves).In these regions the polymer penetrated into the substrate and hadencapsulated many of the fibers of the substrate. However, in theremainder of the polymer in the CD strands and the MD strands, i.e., theportions outside of the intersections, the polymer did not form a strongbond to the substrate. It appeared that there little or no penetrationinto the substrate by the polymer.

When a piece of the composite web corresponding to Area 3 was stretchedin the CD direction (e.g. 100% elongation by hand) and released, thenonwoven substrate formed arcuate portions between the bond points thatcorrespond to the intersections of the CD and MD strands as shown inFIG. 22. For the heavier patterns, such as Area 6 (in which the CDgrooves were larger), the polymer penetrated the nonwoven substrate,encapsulating many of the fibers, over the entire length of the CDstrands. When a piece of the web that corresponds to Area 6 wasstretched in the CD direction and released, the substrate did not formarcuate portions as was seen in samples of the stretched composite webfrom Area 3. The composite web formed by each of the six patterns hadgood elasticity after an initial stretching and relaxation. For each ofthe six patterns, significant portions of the substrate between the CDstrands and MD strands was substantially free of polymer, thus creatinga highly breathable web (because the nonwoven substrate was itselfhighly breathable).

The preceding specific embodiments are illustrative of the practice ofthe invention. This invention may be suitably practiced in the absenceof any element or item not specifically described in this document. Thecomplete disclosures of all patents, patent applications, andpublications are incorporated into this document by reference as ifindividually incorporated. Various modifications and alterations of thisinvention will become apparent to those skilled in the art withoutdeparting from the scope of this invention. It should be understood thatthis invention is not to be unduly limited to illustrative embodimentsset forth herein.

1.-14. (canceled)
 15. A composite web comprising: a substrate comprisinga first major surface; and one or more polymeric structures of athermoplastic composition attached to the first major surface of thesubstrate; wherein each polymeric structure of the one or more polymericstructures occupies an area of the first major surface of the substrate;and wherein the area occupied by at least one polymeric structure of theone or more polymeric structures comprises a bonded area in which thethermoplastic composition of the polymeric structure is attached to thefirst major surface and three or more distinct detached areas extendingfrom the bonded area, wherein the three or more distinct detached areasare cantilevered over but not attached to the first major surface of thesubstrate.
 16. A composite web according to claim 15, wherein each ofthe distinct detached areas comprises a stem comprising a free endsupported above the first major surface of the substrate, wherein thefree end is adapted to engage fibers of a loop material.
 17. A compositeweb according to claim 15, wherein the first major surface of thesubstrate comprises polymeric material with a melt processingtemperature at or below a melt processing temperature of thethermoplastic composition of the one or more polymeric structures.
 18. Acomposite web according to claim 17, wherein the polymeric materialcomprises polymeric film.
 19. A composite web according to claim 15,wherein the first major surface of the substrate comprises a poroussurface, and wherein the thermoplastic composition in the bonded areasof the one or more polymeric structures infiltrates into the porousfirst major surface of the substrate.
 20. A composite web according toclaim 15, wherein the first major surface of the substrate comprisespolymeric fibers with a melt processing temperature at or below a meltprocessing temperature of the thermoplastic composition of the one ormore polymeric structures.
 21. A composite web according to claim 15,wherein the first major surface of the substrate comprises fibers, andfurther wherein at least a portion of at least some of the fibers areencapsulated in the thermoplastic composition within the bonded area.22. A composite web according to claim 15, wherein the thermoplasticcomposition of the one or more polymeric structures comprises one ormore elastomeric polymeric components such that the one or morepolymeric structures exhibit elastic behavior.
 23. A composite webaccording to claim 15, wherein at least one of the distinct detachedareas comprises a barb.
 24. A composite web according to claim 15,wherein the first major surface of the substrate comprises one or moreraised portions and surrounding valleys, wherein the bonded area of theat least one of the one or more polymeric structures is attached to oneof the one or more raised portions.
 25. A closure system comprising: afirst closure element comprising a thermoplastic polymeric structureattached to a first major surface of a first substrate, wherein thefirst closure element occupies an area of the first major surface of thefirst substrate, wherein the area occupied by the first closure elementcomprises a bonded area in which the thermoplastic polymeric structureis attached to the first major surface of the first substrate and adetached area in which the thermoplastic polymeric structure is notattached to the first major surface of the first substrate, wherein aportion of the thermoplastic polymeric structure in the detached areacomprises a first cantilevered tab supported above the first majorsurface of the first substrate; and wherein the bonded area of the firstclosure element, the cantilevered tab of the first closure element, andthe first major surface of the first substrate form a first pocket; anda second closure element comprising a thermoplastic polymeric structureattached to a first major surface of a second substrate, wherein thesecond closure element occupies an area of the first major surface ofthe second substrate, wherein the area occupied by the second closureelement comprises a bonded area in which the thermoplastic polymericstructure is attached to the first major surface of the second substrateand a detached area in which the thermoplastic polymeric structure isnot attached to the first major surface of the second substrate, whereina portion of the thermoplastic polymeric structure in the detached areacomprises a second cantilevered tab supported above the first majorsurface of the second substrate, and wherein the bonded area of thesecond closure element, the cantilevered tab of the second closureelement, and the first major surface of the second substrate form asecond pocket; wherein the cantilevered tab of the first closure elementis located in the second pocket and the cantilevered tab of the secondclosure element is located in the first pocket when the closure systemis in a closed configuration.
 26. A closure system according to claim25, wherein the bonded area of the thermoplastic polymeric structure ofthe first closure element comprises a U-shaped bonded area, and whereinat least a portion of the cantilevered tab of the second closure elementis located within the U-shaped bonded area when the closure system is inthe closed configuration.
 27. A closure system according to claim 25,wherein the bonded area of the thermoplastic polymeric structure of thefirst closure element comprises a U-shaped bonded area, and wherein atleast a portion of the cantilevered tab of the second closure element islocated within the U-shaped bonded area of the first closure elementwhen the closure system is in the closed configuration; and wherein thebonded area of the thermoplastic polymeric structure of the secondclosure element comprises a U-shaped bonded area, and wherein at least aportion of the cantilevered tab of the first closure element is locatedwithin the U-shaped bonded area of the second closure element when theclosure system is in the closed configuration. 28.-31. (canceled)
 32. Aclosure system comprising: a substrate comprising a first major surfaceand one or more polymeric structures attached to the first major surfaceof the substrate, wherein each polymeric structure of the one or morepolymeric structures occupies an area of the first major surface of thesubstrate, and wherein the area occupied by at least one polymericstructure of the one or more polymeric structures comprises a bondedarea in which the thermoplastic composition of the polymeric structureis attached to the first major surface and three or more distinctdetached areas extending from the bonded area in which the polymericstructure is not attached to the first major surface of the substrate,and further wherein, in the three or more distinct detached areas, theat least one polymeric structure is cantilevered over the first majorsurface of the substrate; and a complementary surface comprising one ormore openings capable of receiving the distinct detached areas of theone or more polymeric structures; wherein in a closed configuration, thefirst major surface of the substrate faces the complementary surface,and further wherein at least one of the distinct detached areas of theat least one polymeric structure is located within the one or moreopenings of the complementary surface such that movement of thecomplementary surface and the substrate relative to each other isrestricted.
 33. A closure system according to claim 32, wherein the oneor more openings of the complementary surface comprise fiber loops. 34.A closure system according to claim 32, wherein each of the distinctdetached areas comprises a stem comprising a free end supported abovethe first major surface of the substrate, wherein the free end of atleast one distinct detached area is located within one opening of theone or more openings of the complementary surface when the closuresystem is in the closed configuration.